JP2002373018A - Virtual plant system and virtual plant and remote monitering linking system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To make easily performable the newly rising of a production line or the process change of an existent line, to make easily verifiable the whole of a plant and to make attainable the efficient development of the production line and the shortening of the period for development. SOLUTION: This system is provided with a virtual plant preparing means 22 for preparing a virtual plant, with which a plant is made into data model, and a simulation means 23 for verifying production conditions and physical distribution conditions at least by making that prepared virtual plant 21 perform production simulation. A plurality of any production facilities in the plant are made into dedicated unit constitutive machines combining a modular unit 76 to a main body machine 75 of common specification so that the modular unit can be freely exchanged. The simulation means 23 can verify the production conditions and the physical distribution conditions when the modular unit of the production facility is exchanged.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a virtual factory system which supports the production of a new product, the start-up of a new production line in response to a change of a product, the process change of an existing line, etc., and the convenient operation after construction. And a virtual factory / remote monitoring cooperation system.

[0002]

2. Description of the Related Art In mass-produced products such as mechanical parts, such as bearings and constant velocity joints, a dedicated production line is set up for each product. In such a production line, products of the same kind having slightly different specifications are dealt with by changing the setup or changing the processing conditions. If the change cannot be dealt with due to a change in setup, etc., the production line is rearranged or a new line is started. In the case of products that become new products, a new production line is often launched. When starting up a new line or rearranging an existing line, etc., after designing the equipment and equipment group and evaluating the design contents,
Expand to factories.

[0003] However, since a factory is developed using dedicated equipment for each product, the development period is prolonged. Also,
Process / equipment design tends to be based on evaluation from a single point of view, and often requires redoing after factory deployment. For example, even if the evaluation of individual facilities is correctly performed, a process with poor productivity, a so-called bottleneck process, may occur on the layout of the entire factory, and efficient production may not be performed as a whole factory. Therefore, it may be necessary to start over after the factory deployment. In addition, when deploying factories, in the case of new technology products and new equipment, local engineers can not deal with it, specialized technicians go to the site to provide technical assistance, and there is often a shortage of technicians . In some cases, failures occur after the actual operation after the factory is deployed, and it is not possible to deal with them on site. Various proposals have been made to evaluate these facilities by simulation of virtual facilities. Also, technology for remote monitoring of factories is being developed. However, all of the conventional simulation means are single-purpose simulation means for equipment alone or for the purpose of a process, and cannot perform comprehensive evaluation. Further, the conventional remote monitoring technology is considered separately and independently from the simulation technology before the factory is deployed. Therefore, the simulation result is not reflected in the remote monitoring.

SUMMARY OF THE INVENTION It is an object of the present invention to easily produce a new product, newly start a production line in response to a product change, change a process of an existing line, etc., and also can easily verify an entire factory and improve efficiency. An object of the present invention is to provide a virtual factory system capable of developing a good production line and shortening a development period. Another object of the present invention is to provide a virtual factory / remote monitoring cooperation system that can effectively use the verification result by simulation and can appropriately perform remote monitoring of a factory. Still another object of the present invention is to easily produce a new product, newly start up a production line in response to a product change, change the process of an existing line, etc., and also can easily perform verification of the entire factory to improve efficiency. An object of the present invention is to provide a factory / verification system complex that can develop a good production line and shorten the development period.

[0005]

The present invention will be described with reference to FIG. 1 corresponding to an embodiment. This virtual factory system (1
1) A system in which a plurality of production facilities (72) verify a factory (4) which is a unit configuration dedicated machine in which a modular unit (76) is interchangeably combined with a main unit machine (75) having a common specification. Virtual factory creating means (22) for creating a virtual factory (21) which is a data model of the factory (4); and a virtual factory (2)
A simulation means (23) for verifying at least the production state and the physical distribution state by causing the pseudo production to be performed in 1) is provided. The simulation means (23) is capable of verifying the production status and the distribution status when the modular unit (76) of the production equipment (72) is replaced.
According to this configuration, the virtual factory (2
Virtual factory creation means (22) for creating 1) and simulation means (23) for making the created virtual factory (21) perform pseudo production and verifying production status and distribution status
Therefore, the entire factory can be easily verified. The production equipment (72) of the factory (4) is equipped with a main machine (7
Since it is a unit configuration dedicated machine in which the modular unit (76) is interchangeably combined with 5), the degree of freedom of process change is high. Using such a production facility (72),
The simulation means (23) performs various processes in which the modular unit (76) is replaced in order to make it possible to verify the production status and the distribution status when the modular unit (76) of the production equipment (72) is replaced. The production line can be easily and efficiently verified, and a production line utilizing the features of the unit configuration dedicated machine can be constructed. For this reason, it is possible to easily start up a new production line, change the process of the existing line, etc., in response to the production of new products, changes in products to be produced, etc.
It is possible to develop efficient production lines and shorten the development period. In addition, equipment costs and inventory can be reduced.

The virtual factory creating means (22) and the simulation means (23) have the following configuration, for example.
The virtual factory creating means (22) is a virtual factory (21) which is a model constituted by the functions of the production facilities (72) and the distribution facilities (73) of the factory (4) and the layout data (33) of these facilities. ) To create. The simulation means (23) is a virtual factory (21)
Simulated production to verify the production status and distribution status on the layout. Some of the above-mentioned production facilities (72) constitute a production line (71) by arranging a plurality of production facilities, and a plurality of production facilities (72) which are constituent elements of the production line (71).
However, this is a unit configuration dedicated machine in which a modular unit (76) is interchangeably combined with a main body machine (75) having a common specification. The simulation means (23) includes:
Verification according to various changes of the production line (71) including replacement of the modular unit (76) of the production equipment (72) can be performed.

The virtual factory creating means (22) rearranges the modular unit (76) according to the information of the main machine (75) and the information of the modular unit (76) of the production equipment (72) registered in the equipment database. It is preferable to be able to create models of various unit configuration dedicated machines.

The virtual factory (21) has individual facilities (7
2), a plurality of virtual facilities (3
1) and (32), wherein the simulation means (2)
3) integrates the verification results of the facility simulation units (34) and (35) for verifying the virtual facilities (31) and (32) and the verification results of the individual facility simulation units (34) and (35) and layouts And a general simulation section (36) shown in FIG.

The equipment simulation section (34) for the virtual equipment (31) of the production equipment (72) includes a production equipment (7).
It is preferable that the settable adjustment condition and operation condition of 2) can be set, and verification can be performed according to the set adjustment condition and operation condition. Logistics equipment (7
The equipment simulation unit (35) for the virtual equipment (32) of (3) can also set the settable adjustment conditions and operation conditions of the physical distribution equipment (73), and perform verification according to the set adjustment conditions and operation conditions. Preferably it is possible.

A virtual factory / remote monitoring cooperative system according to the present invention remotely monitors a virtual factory system (11) having any one of the above-described configurations of the present invention and an actual factory (4) corresponding to the virtual factory system (11). Remote monitoring system (5
1) and a linking means for performing a linking process between the virtual factory system (11) and the remote monitoring system (51). In the case of this configuration, the virtual factory system (1
1) Since the coordination means for performing coordination processing between the remote monitoring system (51) and the remote monitoring system (51) is provided, the result of the simulation can be more effectively used for remote monitoring, and the remote monitoring of the constructed factory can be appropriately performed.

In this virtual factory / remote monitoring cooperative system, the remote monitoring system (51) is preferably capable of remote maintenance.

Further, the remote monitoring system (51) includes:
Remote monitoring and remote maintenance can be performed interactively, and on the same screen of the display device, an image of the equipment to be monitored, an image of an operator on the factory side, and text information necessary for monitoring or remote maintenance are displayed. May be displayed side by side. More preferably, the remote monitoring system (51) is capable of transmitting voice.

In the virtual factory system and the virtual factory / remote monitoring cooperation system of the present invention, the products to be produced in the factory may be mechanical parts having rolling elements. Such mechanical components include rolling bearings and constant velocity joints.

The factory / verification system complex of the present invention comprises:
It comprises a real factory (4) and a virtual factory system (11). The real factory (4) is a production facility (72)
And a production line (71) comprising logistics facilities, and a plurality of production facilities (72) serving as line components are
This is a unit construction dedicated machine in which a modular unit (76) is interchangeably combined with a main machine (75) common to each other. The virtual factory system (11) has one of the above-mentioned configurations in the present invention. In the factory / verification system complex having this configuration, a plurality of production facilities (72), which are line components of the real factory (4), have a modular unit (76) with respect to a common main body machine (75).
Since the unit is a unit dedicated to unit exchange, the process of the production line (71) can be easily changed by exchanging the modular unit (76). The combination of the production facility (72) that can easily perform such a process change and the virtual factory system (11) of the present invention makes it possible to shorten the factory development period and optimize production.

[0015]

An embodiment of the present invention will be described with reference to the drawings. First, the virtual factory system 11 will be described with reference to FIG. The virtual factory system 11 is a system for verifying productivity and the like by simulation when newly starting up or changing a production line, reconstructing an existing line, and the like. The virtual factory system 11 and the remote monitoring system 51 constitute a design / operation support system 50 for factory equipment. The virtual factory system 11 includes a virtual factory creation unit 22 that creates a virtual factory 21 that is a data model of the factory 4.
A simulation unit 23 is provided for causing the created virtual factory 21 to perform pseudo production and at least verify the production status and the physical distribution status. The virtual factory system 11 further includes an evaluation unit 24, a factory deployment support unit 25, and a communication unit 26.

The virtual factory 21 serving as a data model is intended for the factory 4 including only one production line 71, or is intended for the factory 4 including a large number of production lines 71. May be. For example, when a factory 4 including a large number of production lines 71 as shown in FIG. 16 is targeted, the factory 4 may be divided into a plurality of areas E, and a virtual factory 21 may be provided for each area E.

The virtual factory 21 includes the production facilities 72 of the factory 4
And the functions of the logistics equipment 73, and these equipments 72,
The model has 73 layout information. The production equipment 72 generally refers to equipment for producing goods, such as machine tools,
Includes equipment for processing sheet metal working machines, assembling machines, inspection machines, and heat treatment. The distribution facility 73 generally refers to a device for transporting goods in a factory and a facility for storing the same. The distribution facilities 73 include those that constitute the production line 71 together with the production facilities 72, and those that are outside the production line. The logistics equipment 73 includes the production equipment 7
It also includes a conveyor such as a conveyor for transporting goods between the two, an unmanned transport cart for transporting goods between production lines, a manned forklift, and an automatic warehouse. Any one of the plurality of production facilities 72 in the factory 4 is a unit configuration dedicated machine in which a modular unit 76 is interchangeably combined with a main body machine 75 having a common specification, and the process of the production line 71 can be changed. ing. Details of the unit configuration dedicated machine and process changes will be described later.

The virtual factory 21 is composed of virtual facilities 31, 32, which are data models respectively corresponding to the production facilities and the distribution facilities in the factory, and layout information 33 of each facility. The virtual facilities 31 and 32 have data of the functions of the actual equipment, and setup condition and operation condition data that can be set for the equipment. The operating conditions are
When parameters are set in actual equipment, it is desirable to have data on the types of settable parameters and setting ranges. The virtual equipment 31 has data of the function of the control panel of the actual equipment, and includes the operation program when the actual equipment is numerically controlled by the operation program. Virtual facilities 31, 3
Of the two, the virtual equipment 31 corresponding to the production equipment is assumed to have information on processing conditions as operating conditions. The virtual facilities 31 and 32 have data on the shape of the actual equipment. This shape data may be data to be displayed on the screen display means.

FIG. 2 shows a specific example of the virtual facility 31. The virtual facility 31 is a facility information section 3 that is a group of information of the facility itself.
1a and a setting information section 31b which is an information group set for the equipment. The equipment information section 31a is provided with equipment structure information on the structure of the equipment, equipment function information on the functions of the equipment, control device information as information on the control device of the equipment, and shape information on the shape of the equipment. Compatibility information, which is information on compatible products of equipment, is provided. The setting information section 31b is provided with adjustment information that is information for performing installation adjustment of equipment and adjustment of other units, and condition setting information that is information on conditions to be set in the main body of the equipment or the control device of the equipment.

In FIG. 1, simulation means 23
Has a function of simulating the production status on the layout and the distribution status resulting from the production by causing the virtual factory 21 to perform pseudo production. The simulation means 23 includes the individual virtual facilities 31 and 32
Equipment simulation part 3 that simulates
4, 35 and individual equipment simulation units 34, 35
And an overall simulation unit 36 that integrates the verification results of the above and shows on the layout. The simulation means 23 has a function of displaying, on a screen of the display device, the result of the simulated production, a layout diagram, and a display section showing the flow state of the goods in each section on the layout diagram. The layout diagram is preferably displayed as a three-dimensional model. The display unit showing the flow state of the object shows, for example, a diagram in which the work is stacked at each position in the layout diagram,
The work amount may be indicated by the number of stacks, or may be indicated by a bar graph or the like at each position. The simulation means 23 is a virtual factory 21
From the whole to each facility or component of the facility,
It is preferable to be able to expand and display small portions in a hierarchical manner. It is preferable that a diagram of each facility can be displayed as a three-dimensional model. FIGS. 9 and 10 show screen display examples of the entire layout of the virtual factory 21 by the simulation means 23 and screen displays of a production system including a plurality of adjacent production lines. In these figures, the displayed images are denoted by the same reference numerals as those assigned to existing facilities.

In FIG. 1, the virtual factory creating means 22 comprises:
This is a means for creating a virtual factory 21 of a data model that can be simulated by the simulation means 23 from data on equipment registered in the equipment database. The evaluation unit 24 is a unit that performs a predetermined evaluation on the result of the simulation, for example, evaluation of cost, productivity, workability of an operator, and the like. Factory deployment support means 25
Is a means for providing support for facilitating the use of the information obtained by the virtual factory system 11 during factory deployment.

FIG. 3 shows an example of a hardware configuration of a design / operation support system 50 for factory equipment including the virtual factory system 11. A computer configuring the virtual factory system 11 and the remote monitoring system 51 and a computer configuring the equipment database 17 and the product database 18 are connected to the local area network 60 in the business establishment 2. Although the virtual factory system 11 and the remote monitoring system 51 are shown as one representative in the figure, these systems 11 and 51 may be configured to be distributed on a plurality of computers. . Further, each of the databases 17 and 18 may be any database that is logically recognized as one, and may be a physically configured database. The local area network 60 has a firewall 68,
A router 69 and the like are connected to the communication network 3 which is one of communication line means with the outside of the business office 2, and communication management is performed by a web server 67. The equipment database 17 is a means for registering information on various types of production equipment and physical distribution equipment. In addition to information on the equipment itself, information on accessory parts such as jigs and tools is also registered. The equipment database 17 may be registered to include the processing program of the production equipment. The product database 18 stores model numbers, shapes, processing orders, materials,
This is a means for registering functions, accuracy, etc.

The remote monitoring system 51 is provided for the actual factory 4
This is a means for remotely monitoring at least the production status and the physical distribution status on the layout of the facilities 72 and 73 shown in FIG. The production status and the distribution status include the status of in-process products and finished products. As the above production situation,
Productivity and production performance can be monitored. The production results include, for example, the production results of work-in-progress, the arrival status of parts, the operation status of each facility, and the progress status with respect to the production plan, in addition to the product production results. Remote monitoring system 5
1 has a function of comparing the monitoring result of the remote monitoring with the verification result by simulation when the actual factory 4 is constructed in conformity with the virtual factory 21. This comparison function may be provided in the virtual factory system 11 instead of being provided in the remote monitoring system 51, or may be provided in both systems 51, 11 or in a system different from these systems 51, 11. good.

As shown in FIG. 4, the remote monitoring system 51
Has a remote monitoring means 52, a monitoring result analyzing means 53, and a remote maintenance means 54. Remote monitoring system 51
May be further provided with a remote driving means 55. The monitoring result analysis means 53 analyzes, for example, information obtained by monitoring, and outputs a countermeasure such as condition change data. The analysis result output from the monitoring result analysis means 53 may be input to, for example, the remote maintenance means 54 and automatic remote maintenance may be performed via the remote maintenance means 54. The output of the analysis result may be sent to a technician for remote maintenance. You may make it show as support information.

FIG. 5 shows the concept of monitoring by the remote monitoring system 51. The remote monitoring system 51 is capable of monitoring and remote maintenance using images, sounds, machine-generated signals, and the like. Each production facility 7 in the factory 4 to be monitored
Monitoring sensors 63 are provided for 2 and the distribution facility 73. The monitoring sensors 63 include, for example, a monitor camera 63a, a microphone 63b, and a sensor 63 in the facility.
There is c. The monitor camera 63a includes one that captures the operation status of the production facility 72 and one that captures the flow of materials, products, and the like in the distribution facility 73. As the microphone 63b, there are a microphone for recording the sound around the production facility 72 and a sound generated by the facility, and a microphone for recording the logistics facility 73. The in-facility sensor 63c is provided in each of the facilities 72 and 73 to detect a situation in the facility, and may be sensors used for controlling the facility. Equipment sensor 6
Reference numeral 3c includes, for example, rotation speed detecting means for motors, an ammeter, limit switches, a temperature sensor, a vibration sensor, a microphone, and the like. Although only one in-facility sensor 63c is shown in the figure as a representative of each facility 72, a plurality of in-facility sensors 63c are generally provided. These monitoring sensors 63 are connected to the communication network 3 outside the factory via the local area network 61 in the factory 4 and to the local area network 60 in the business office 2 where the remote monitoring system 51 is installed. .

In the remote monitoring system 51, an interactive terminal 52 on the factory 4 side operated by the operator and an interactive terminal 53 on the monitoring side can interactively perform remote monitoring and remote maintenance. ing. These interactive terminals 5
Each of the computers 2 and 53 may be an independent computer or a computer attached to a control panel, and includes cameras 52a and 53a for capturing an image of an operator and microphones 52b and 53b for transmitting the voice of the operator.

FIG. 6 shows an example of a screen of the display device of the interactive terminal 53 on the monitoring side.
a, an image 54b of the operator on the factory side, and character information 5
4c can be displayed side by side. Character information 54c
Is data of equipment required for monitoring or remote maintenance.
The display portions of the images 54a and 54b and the character information 54c may be divided by windows, or may be divided by frames in the same window. Like the interactive terminal 53 on the monitoring side, the interactive terminal 52 on the factory side can display an image of the equipment to be monitored, an image of the operator on the monitoring side, and character information side by side.

As shown in FIG. 7, the virtual factory system 11
The remote monitoring system 51 and the remote monitoring system 51 are linked to each other by a linking unit 66. The virtual factory system 11 and the remote monitoring system 51 constitute a virtual factory / remote monitoring link system 56. The linking unit 66 compares the verification result based on the simulation by the virtual factory system 11 with the remote monitoring result by the remote monitoring system 51. The coordinating means 66 may constitute the remote monitoring system 51, and the virtual factory system 11
May be configured. The comparison between the verification result and the remote monitoring result may not be a direct comparison but may be a comparison between an evaluation result obtained by evaluating the verification result and an analysis result obtained by analyzing the remote monitoring result. Further, the coordinating means 66 has a function of obtaining a difference based on the comparison and performing a predetermined process according to the difference determined based on the comparison result. The coordinating unit 66 may unify the screen content of the display device at the time of simulation in the virtual factory system 11 and the screen content of the display device at the time of remote monitoring in the remote monitoring system 51. The unified screen example is displayed on the virtual factory system 11 and the remote monitoring system 51.
Will be described together with a more detailed example.

As shown in FIG. 8, the virtual factory system 11
Can display, on the screen of the display device 11a, a model image 57a of the equipment at the time of the simulation and a model image 57b of the operation panel in the control device of the equipment. The virtual factory system 11 is designed to specify the model image 57b of the operation panel with a pointing device such as a mouse, and to set conditions corresponding to an actual operation panel and operate virtual facilities at the time of simulation. The remote monitoring system 51 can display an actual equipment or a modeled equipment image 58a of the equipment and an actual operation panel or a modeled operation panel image 58b of the equipment. Further, the remote monitoring system 51 specifies the image 58b of the operation panel with a pointing device or the like,
It is possible to set conditions and operate equipment operation corresponding to the actual operation panel. The unification of the screens of the virtual factory system 11 and the remote monitoring system 51 is performed by the cooperation means 66.
(FIG. 7). When the remote monitoring system 51 shows the equipment and the operation panel with model images instead of the captured images as they are, it is assumed that the cooperation unit 66 unifies the images with the images in the virtual factory system 11. Further, the coordinating unit 66 may display the simulation screen in the virtual factory system 11 and the monitoring screen in the remote monitoring system 51 on the same display device or an adjacent display device.

Next, with reference to FIG.
The operation method will be described. In this method, as shown in FIG. 2A, there are facilities and equipment groups, and in response to the development of a new product or the production plan (FIG. 2C), the actual factory (FIG. 2B) This is a method of starting a new production line, changing the line, etc., and operating the actual factory. The equipment and equipment group shown in FIG. 2A may be already installed or stored in a real factory, or may be in a design process. Among these facilities, a part or the whole of the production facility is a unit construction dedicated machine described above with reference to FIG. The method of designing and operating the factory equipment includes a virtual factory verification process (S1), a factory deployment process (S2), and a remote monitoring process (S3). This method of designing and operating factory equipment is applied to a wide-area factory production management system described later.

In the virtual factory verification process (S1), a part or the whole is constituted by the functions of the production facilities 72 and the distribution facilities 73 of the newly designed factory 4 (FIG. 1) and the layout information 33 of these facilities. A virtual factory 21 as a model is created. The virtual factory 21 is simulated by simulation means 23 to verify various situations on the layout. It is preferable that the simulation of the pseudo production can be performed as close to the actual factory 4 as possible. However, at least the production status and the distribution status on the layout of the facilities 72 and 73 can be simulated. The results of the simulation are based on the overall layout of the factory 4 illustrated in FIG. 9 and FIG. Are displayed so that they can be observed in figures, symbols, characters, numerical values, and the like. By simulating the production situation and the distribution situation on the layout in this way, it is possible to find an inefficient place in the production line 71, and to improve the place, the production line 7 is improved.
1 can improve the efficiency. In the simulation of the pseudo production, adjustment conditions and operating conditions of each of the facilities 72 and 73 are set, and pseudo production is performed according to the set conditions. For example, setup, control parameters, operation tact, and the like are set and pseudo production is performed. When the production equipment is to be program-controlled by the control device of the NC device, it is preferable to perform pseudo production by an operation program such as an actual machining program. The execution speed of the operation program may be higher than the actual speed for the simulation. The overall simulation unit 36 in the simulation means 23 (FIG. 1) causes a delay to occur in a part of the production line 71 and, if the delay affects subsequent processes, reflects the influence on the simulation result.

In the preliminary verification by simulation, not only the production status and the distribution status of the work on the layout, but also the transportation of the work-in-progress between the production lines and in the factory as well as the operation status of the people as well as on the production line 71 are verified. Is preferred. In the preliminary verification by simulation, it is preferable to verify the relation between the quality of the product to be produced and the setting conditions, the relation between the productivity and the setting conditions, and the interrelationship between these quality, productivity, and design conditions. In this way, through simulation verification, verification of layout production status and logistics status, identification of bottleneck processes, verification of processing methods, processing processes, optimization of processing conditions, logistics, inventory evaluation, human work efficiency Verification, productivity evaluation, production cost calculation, etc.

In the virtual factory verification process (S1), if the contents of the factory design are not satisfactory, various setting conditions are changed, and if necessary, the process of the production line 71 is changed to perform verification. Do. In the verification of the process change of the production line 71, if the process of the production line 71 can be changed by changing the form of the production equipment 72, the verification according to the change in the form is performed. For example, when the production facility 72 is a unit configuration dedicated machine, verification is performed when a process is changed by replacing the modular unit 76.

In the virtual factory verification process (S1), it is preferable to perform verification in accordance with operating calendar conditions and verification in accordance with equipment abnormality. The operation calendar condition is a condition such as a holiday condition in one year, a start time, an end time in one day, a break time in the middle of a lunch break, and the like.

In the factory development process (S2), each of the facilities 72 and 73 and the actual factory 4 of the layout that match the virtual factory 21 verified as described above are constructed. Each equipment 7
The setting contents of 2, 73 are also the setting contents at the time of simulation. In the factory deployment process (S2), the information of the operating conditions set in the virtual factory verification process (S1) is
2 may be set by transfer to the second control device via data communication means. The virtual factory verification process (S
The installation conditions obtained in 1) correspond to the actual
If instructions are given to the information processing device or portable information processing device near 2, 73 by displaying figures or characters, installation can be easily and correctly performed.

In the remote monitoring process (S3), various types of remote monitoring of the actual factory 4 constructed through the virtual factory verification process (S1) and the factory deployment process (S2) are performed. For example, the production status and the distribution status on the layout of each of the facilities 72 and 73 are remotely monitored, and the monitoring result is compared with the verification result obtained by the simulation. In addition, it remotely monitors the operation status of each of the facilities 72 and 73, the quality of the produced work, and the like. In this remote monitoring step (S3), it is preferable to perform remote maintenance of the equipments 72 and 73 using the monitoring results, and it is also possible to perform remote operation of the equipments 72 and 73. Remote maintenance includes operating conditions, machining conditions,
This includes processing for remotely changing parameters and processing for instructing these change conditions on information processing equipment in the factory 4. In the remote monitoring step (S3), when there is a difference between the monitoring result and the verification result at the time of the simulation, the simulation means 23 causes the virtual factory 21 to perform the pseudo production again to perform the verification, and according to the verification result. Remote maintenance may be performed. At the time of the above-mentioned pseudo production again, the setting conditions and the like may be appropriately changed from those at the time of factory development.

An object product to be produced in the factory 4 using the virtual factory system 11 and the remote monitoring system 51 is a mechanical part having a rolling element, for example, a rolling bearing or a constant velocity joint, and one of the production facilities 72 is a grinding machine. An example of setting conditions and monitoring contents in a certain case will be described. In the case of such a grinding machine, a tool rotation speed, a tool feed speed, a tool feed amount, a dress condition, a spindle rotation speed, and the like are set as operating conditions or machining conditions. Further, as the conditions of the workpiece, a product name, a weight, a groove grinding width, a specific heat, an expansion coefficient, a dimensional accuracy of each part, and the like are set. Further, processing power, product dimensions during processing, processing temperature, processing time, and the like are set as information for grasping the processing state. In the remote monitoring, such conditions are monitored. By remotely monitoring these conditions and making settings changeable by remote control, remote maintenance can be performed for various problems and the like.

As described above, the use of the virtual factory system 11 makes it possible to easily verify the entire factory. For this reason, efficient start-up of a new production line or factory change such as process change of an existing line can be performed easily and in a short time, and it is not necessary to repeat the process after the factory expansion. In particular,
If the production equipment 72 is prepared with a high degree of freedom of change, such as a unit configuration dedicated machine, and if the virtual factory system 11 can perform the verification when the process change of the production line 71 is performed, the factory is expanded. The development period for doing so is greatly shortened. In addition, since the actual factory 4 that matches the virtual factory system 11 verified by the simulation is constructed, the actual factory is remotely monitored, and the monitoring result is compared with the verification result at the time of the simulation. Can be used for remote monitoring, and the built factory 4 can be appropriately monitored remotely. For example, when there is a difference between the result of the remote monitoring and the result of the simulation, the simulation can be performed again with the setting conditions of the virtual factory 21 changed, and appropriate maintenance can be performed. In the remote monitoring by the remote monitoring system 51, by providing a remote maintenance function, a remote technical expert,
Using advanced analysis equipment, appropriate maintenance can be quickly performed based on monitoring results. Thereby, the production technology of each factory 4 can be enhanced.

The wide area factory production management system 1 using the virtual factory system will be described with reference to FIGS. The wide area factory production management system 1 comprehensively performs production management and production technical support of a factory 4 which is a production base in various countries in the world. This wide area factory production management system 1
Is a production management system that uses a virtual factory system.
It is set up at the business establishment 2 including the production supervision department. The wide area factory production management system 1 is connected via a communication network 3 to offices such as factories 4 and sales offices 5 in various places. In addition, logistics offices 6 in various places, mobile terminals 7 as information terminals handled by individuals, Also, it is connected to a material supplier office 8 such as a parts maker. The factories 4 in each region are factories set up around the world.

The communication network 3 may be a virtual private network (VPN), whether it is the Internet or a dedicated line network.
(Virtual private network)). The communication network 3 is, for example, an Internet VPN that is connected to a local area network of each business office via the Internet while securing security.
Are used.

As shown in FIG. 13, the wide area factory production management system 1 includes an integrated virtual factory system 12 in which a plurality of virtual factory systems 11 corresponding to actual factories 4 in various places are integrated. The integrated virtual factory system 12 includes a virtual factory system 11 corresponding to a factory to be newly constructed, in addition to the virtual factory system 11 corresponding to the actual factory 4. The wide area factory production management system 1 also includes an integrated remote monitoring system 13 for remotely monitoring an actual factory 4 in each region.
An order management system 14 for managing the order information of each sales office 5, a logistics monitoring system 15 for managing and monitoring the logistics situation in each region, a production planning means 16,
Various databases (not shown in the figure) are provided.
The integrated remote monitoring system 13 is configured as an aggregate of remote monitoring systems 51 respectively corresponding to the actual factories 4. The virtual factory system 11 and the remote monitoring system 51 have the above-described configurations together with FIGS. The integrated virtual factory system 12 and the integrated remote monitoring system 13 may share the components of the virtual factory system 11 or share the components of the remote monitoring system 51 with the integration.

FIG. 14 shows an example of a hardware configuration of the wide area factory production management system 1. Wide area factory production management system 1
Is an integrated and developed system for supporting design and operation of factory equipment shown in FIG. Each computer on the local area network 60 has an integrated virtual factory system 1
2, an integrated remote monitoring system 13, an integrated order management system 14, a physical distribution management system 15, and a production planning means 16. In addition, various databases such as a facility management database 17A, a product management database 18, an order management database 19, a distribution management database 20,
And the virtual factory database 64 are connected.

The order management system 14 is a means for centrally managing the order information of each sales office 5 which is a business office relating to orders. The sales offices 5 are all business offices scattered around the world, regardless of the size. The office 5 may be a personal terminal or a large-scale office in which order information of a plurality of offices is collected. The order information managed by the order management system 14 includes information such as product type, quantity, delivery price, delivery date, delivery location, compatible product availability information, and special circumstances. The order information is registered and managed in the order management database 19 by the order management system 14.

The physical distribution management system 15 is a system for comprehensively managing, as the physical distribution information, information on transportation and storage between the delivery destination of the product of each factory 4, parts and materials, and the source. The physical distribution management system 15 stores, as logistics information, product inventory of each factory 4, inventory of work in process, parts,
Material inventory information is also comprehensive. The physical distribution information is registered and managed in the physical distribution management database 20 by the physical distribution management system 15. If identification codes are attached to all products, it is possible to instantly grasp where, what, and how much.

The product control database 18 stores various information on products that can be produced in each factory 4, such as product type, product number, size, performance, accuracy, materials required for manufacturing the product, processing methods, This is a database in which information on processed parts and the like is registered.

The equipment management database 17A registers equipment in the actual factories 4 in various places to be subjected to the production plan, setup information of the equipment, an operation program of the equipment, information specific to individual equipment (so-called “kuse”), and the like. Have been. For example, the equipment management database 17A stores information on types, performances, dimensions, setup changes, and the like of each equipment already installed and stored equipment in each factory 4, and information on each factory or production of the installed equipment. Layout information for each line is registered. Equipment Management Database 17A
If the equipment can be changed in form by replacing the modular unit 76, information on the changeable form is also registered. Equipment Management Database 17
Regarding A, even if it is not actually installed in any of the factories 4, information about the equipment to be considered for installation is also registered.

The virtual factory database 64 is a database in which information of each virtual factory 21 which is a data model created by the integrated virtual factory system 12 is registered including its setting information.

The integrated remote monitoring system 13 obtains information on at least the production results, the work-in-progress status, the parts receiving status, the stock status, and the operating status in the actual factory 4. The factory data collected by the integrated remote monitoring system 13 is stored in the operation status database 65 as it is or after data processing. Each remote monitoring system 51 of the integrated remote monitoring system 13 preferably has the above-described remote monitoring function and remote maintenance function. By providing each of the remote monitoring systems 51 of the integrated remote monitoring system 13 with such a function, the monitoring and maintenance of each factory can be centrally managed.

The production planning means 16 causes the integrated virtual factory system 12 to perform verification according to information obtained from the integrated remote monitoring system 13, the integrated order management system 14, and the integrated distribution monitoring system 15, and according to the verification result. This is a means for automatically generating a production plan to be assigned to each actual factory 4.

As shown in FIG. 15, the production planning means 16 has a production planning unit 16a, a plan correction unit 16b, a production instruction unit 16c, and a production management unit 16d. The production planning unit 16a includes an integrated remote monitoring system 13, an order management system 14, and a distribution management system 15.
The integrated virtual factory system 12 according to the information obtained from the
Is performed, and the set production plan rule 16aa
Means for automatically drafting a production plan in accordance with The production plan is a production plan distributed to each factory 4. The production plan rule 16aa includes the production cost, the production capacity of each factory 4,
Selection procedures are set for items such as distribution, materials, taxes, etc., taking into account the importance. The production plan drafting unit 16a determines whether or not the actual factories 4 in various places can change the process according to a predetermined standard. If the process can be changed, the production situation when various processes are changed is determined. Is performed by the integrated virtual factory system 12, and then a production plan is drafted in accordance with the production plan rule 16aa. In addition, the production planning unit 16a
Causes the integrated virtual factory system 12 to perform verification including jig and tool change of each facility, change of setting conditions, change of operation program, and the like within a predetermined range, and according to the production plan rule 16aa. It is intended to draft a production plan. In particular, any one of the actual factories 4 in each region includes, as the production equipment 72, a unit configuration dedicated machine in which a modular unit 76 is interchangeably combined with a main unit machine 75 having a common specification. In the case where the process can be changed, the production plan is to be drafted in accordance with the verification of the production situation when the process is changed. When the product is composed of a plurality of parts, the production plan drafting unit 16a can also draft a production plan for dividing the factory 4 that produces each part.

The plan correction unit 16b is a part of the production planning unit 16
This is a means for changing the production plan drafted in a, by inputting an operator, or giving an instruction such as a condition change by the input of the operator, and causing the production plan drafting section 16a to re-plan.

The production instructing section 16c sends a production instruction S for each factory 4 in the production plan determined and determined to the corresponding factory 4
Means to send to The processing instruction S may be added to the production instruction S as shown in FIG. In particular, in the case of a product that is first produced by the factory 4 to which the production instruction S is given, the processing technology support information Sa is added. The processing technology support information Sa is, for example, processing condition information or address information of a storage area of a database in which the processing conditions are registered.

The production management section 16d is a means for managing the production status as a whole of the individual factories 4 and a set of these factories 4 in comparison with the production plan. Production management department 16d
Sends a correction instruction of the production instruction S to any one of the factories 4 so that if a faulty facility occurs as a result of monitoring by the integrated remote monitoring system 13, the production delay due to the faulty facility is compensated by another facility. It is also possible to have an automatic repair function for changing the process of the production line and changing the operation procedure such as the processing program of the production equipment. In addition, when the automatic repair in the case of the occurrence of the faulty equipment can be performed in the same factory 4, the integrated remote monitoring means 13 performs the process of the production line so as to compensate for the production delay caused by the faulty equipment by another equipment. It may have an automatic repair function for changing and changing operation procedures such as a processing program of a production facility.

The production management unit 16d may have a function of monitoring the progress of production via the integrated remote monitoring system 13 and automatically adjusting the line tact of the production line 71. This automatic adjustment function may be provided in the integrated remote monitoring system 13. For example, each remote monitoring system 51 may have an automatic line tact adjustment function, and each factory 4 may have an independent line tact adjustment function.

According to the wide area factory production management system 1 configured as described above, a production system with a high degree of freedom can be obtained by centrally managing the entire world. That is, it is possible to optimally distribute production to the factories 4 in various places, thereby reducing costs and shortening the delivery period. Also, regardless of the production at any factory 4,
Stable quality is obtained.

The arrangement and effects of the above system will be organized and supplemented. The basics are the following four items. 1. Production equipment that can be freely changed in production location and form according to demand and production cost. 2. Design of the optimal production system by the virtual factory system 11. 3. Strengthen production technology by remote monitoring and remote maintenance. 4. Global and dynamic production planning through sales, distribution, sharing and transparency of production information.

The specific contents of each of the above items will be described. (1) Flexible production system (adoption of unit configuration dedicated machines, downsizing and intelligentization).・ In factory 4, which is each production base, product change, process change,
Facilities that can flexibly respond to changes in production bases are located. It is desirable that the production equipment 72 be compact and low cost.・ Collect, analyze, and compare equipment information and quality information from all over the world from a remote location, and automatically adjust all equipment to optimal conditions (states).・ Equipment and equipment groups are self-supporting, and surface quality and processing efficiency are estimated based on equipment information and quality information, and feedback and feedforward are applied to the processing conditions and aims of the equipment.・ When equipment failure occurs, the equipment is automatically rearranged so that the surrounding equipment complements the process. (2) Virtual factory system 11, integrated virtual factory system 1
Evaluation and design by 2 ・ Layout verification using a three-dimensional model for the entire factory 4 is possible.・ Optimization of processing method, process and conditions can be performed based on evaluation by processing simulation.・ It is possible to identify the bottleneck process by simulated production and evaluate the inventory to optimize the logistics.・ Maximize work efficiency by analyzing the motion of human work.・ Comprehensive verification enables accurate calculation of productivity and manufacturing cost.

(3) Remote monitoring and remote maintenance by the remote monitoring system 51 and the integrated remote monitoring system 13. -Remote monitoring of equipment, equipment group, process operation status, equipment information, quality information through a network, and image and audio transmission equipment that allows mutual confirmation of local video and sound from engineers in remote locations Can receive technical support, and analyze, evaluate, and correct equipment status, perform work orders, and change programs. -If the remote monitoring system 51 is arranged at one place or several places in the world, maintenance can be performed for 24 hours. It is also possible to automatically draft a maintenance plan for the entire factory and issue work instructions based on maintenance information collected by the remote monitoring system 51 from the equipment. -From the factory 4 which is the production base, it is also possible to analyze and evaluate equipment by using analysis tools and databases owned by the technical department and the company from a remote place via a network. (4) Global production system.・ Business information and production progress (actual results, logistics) are disclosed as real-time information, and based on this, the production planning means 16 of the wide area factory production management system 1 creates a production plan in consideration of customer requirements, production and distribution costs. Automatically rebuilds and instantly assigns and directs plans across borders. -The factory 4 automatically reconstructs the current plan into the most efficient plan in response to the instructed change in the production plan, and instructs the site. -Setup information of facilities and equipment groups-Programs-Production equipment-specific information is centrally managed or shared worldwide by a database server, and necessary information is exchanged from this data server based on production plans to change processes. , Change the type.

Next, specific examples of the factory 4 and the facilities 72 and 73 will be described with reference to FIGS. FIG. 16 is a layout diagram showing the entire factory 4 in which a number of production lines 71 are installed. The factory 4 is, for example, a factory that produces rolling bearings. As the production line 71, there are an inner ring production line, an outer ring production line, a rolling element production line, a cage production line, a bearing assembly line, and the like of the bearing. Each is provided with a plurality. One logistics facility 73, the automated warehouse 73 ₆ is provided.

FIG. 17 shows a part of the production line group in the factory 4 in FIG. The figure shows two production lines 71
A production line group in which (71 ₁ , 71 ₂ ) are juxtaposed is shown. Each production line 71 includes a plurality of production facilities 72 and distribution facilities 73. Storage facilities 73 ₁ and the transport device 73 ₂ is provided as the logistics facility 73. Storage facilities 73 ₁ referred to in this specification, such as dosing device, equipment intended to include also functions and other functions to perform temporary storage for such charged. Storage facility 73 _1, even those that do a small amount of storage, may be an automated warehouse or the like for a large amount of storage. In this example, the storage facility 73 ₁ is a facility for storing a work such as a material, a work in process, or a product.
It is arranged side by side with the production equipment 72. Transfer device 73 ₂
Is a device that transports a work between the production facilities 72 or between the production facility 72 and the storage facility 73 ₁ . Each transport device 73 _2, for example, a conveyor or chute, etc., is shown an example in which the linear conveyor.

Each of the production equipments 72 includes a machine, a plastic working,
Alternatively, it is a facility for producing an object by heat treatment or the like, for example, a machine tool. The example shown is for each production line 71 ₁ , 7
1 ₂ is a inner ring production line and the outer ring production line in each rolling bearing. Production equipment 72 ₁ in the first production line 71 _1, 72 _2, 72 ₄ are respectively an inner ring groove grinding machine, the inner ring inner diameter grinding machine, a inner ring groove superfinishing machine, the production facility in the second production line 71 ₂ 72 ₃ ,
72 ₅ are each outer groove grinding machine, and the outer ring groove superfinishing machine.

The production equipment 72, which is a line component of each of the production lines 71 ₁ and 71 ₂ , is a dedicated machine having a unit configuration in which a modular unit is interchangeably combined with a main machine having a common specification. The process can be changed by exchanging 72 modular units. Each production facility 72 does not necessarily have to have a main body machine having a common specification with all the production facilities 72 in the production line 71, and has a main body machine having a common specification among a plurality of production facilities 72. Anything is fine. Further, as a line component, a production facility without a main body machine having a common specification may be included. In this example, as the grinding machine to become three production facilities 72 ₁ to 72 ₃ have a common body machines together, two production facilities 72 ₄ as a super finishing machine, 72 ₅ have a common body machines together is there.

FIGS. 18 to 20 show a specific example of the production equipment 72 which is a unit-structure-dedicated machine having a main machine with common specifications. The production facilities 72 _{1 to} 72 shown in these drawings
Reference numeral ₃ denotes an inner ring groove grinder, an inner ring inner diameter grinder, and an outer ring groove grinder shown in FIG. 17, respectively.
FIG. 21 shows the main body machine 75. These production facilities 7
Reference numeral 2 denotes a dedicated machine having a unit configuration in which a modular unit 76 is interchangeably combined with a main machine 75 having a common specification. The common body machine 75 includes a common bed 77 and a common unit 78. The modular unit 76 and the common unit 78 have various functions. In the common unit 78, reference numerals in the specification and the drawings use the codes indicating the individual types when it is necessary to distinguish the individual types of the units.

As shown in FIG. 21, the common unit 78
A headstock 79, a spindle spindle 80, and a slide table 81 that can be driven forward and backward in two orthogonal axes directions. The slide table 81 includes a first table 81a provided on the bed 77 so as to be able to advance and retreat in a predetermined axial direction (Z-axis direction), and a direction orthogonal to the axial direction (Z-axis direction) on the first table 81a. It has a two-stage configuration with a second table 81b mounted to be able to move forward and backward in the (X-axis direction), and has a drive source such as a servo voter in each axial direction.
The loading unit 82 may constitute the main body machine 75 as one of the common units 78, or may be constituted as a replaceable modular unit. When the loading unit 82 is a common unit 78, the loading unit body is a common unit, and the loader chucks 82a to 82c (FIG. 1).
8 to 20) are replaceable.

As shown in FIG.
The production equipment 72 is connected to the inner ring groove grinder 72₁If so, common
Dedicated modular unit for main machine 75 of specifications
As a wheel 76, a grindstone spindle 83A and a rotating low
For the Tali dresser 84A and the loading unit 82
The dedicated replacement part 82a to be assembled is assembled. As shown in FIG.
Grinding the inner ring inner diameter of the production equipment 72 dedicated to unit configuration
Panel 72 _Two, The main machine 75 with common specifications
And a dedicated grinding wheel spindle 83B and a fixed dresser
84B and exclusive exchange for loading unit 82
The part 82b and the after gauge 85B are assembled.
As shown in FIG.
The outer ring groove grinder 72_ThreeIf the
A dedicated grindstone spindle 83C and turning for the machine 75
Type rotary dresser 84C and loading unit
82, a dedicated replacement part 82c and an after gauge 8
Assemble with 5C.

Note that the grindstone spindles 83A to 83C serving as the dedicated modular units 76 may have the same configuration, but use different functions because the required capabilities are different depending on the processing. Is preferred. It is desirable that each of the grindstone spindles 83A to 83C be of a built-in motor type. The main spindle 80 may be of a built-in type or of a motor type. It is desirable that these motors are driven by an inverter. Loading unit 8
2 may be one of the modular units 76 as a whole. Slide table 81 in main machine 75
, When the main shaft position is the same, the required stroke position, if the inner ring groove grinder 72 ₁ and the inner ring inner diameter grinding machine 7
Because significantly different between the case of a _two-2, shall have a corresponding possible stroke range in any case the two.

As described above, the production equipment 72 of the unit configuration dedicated machine in the production line 71 is manufactured by assembling the dedicated modular unit 76 with the main machine 75 having the common specification. By exchanging, it becomes a dedicated machine with different functions. Therefore, the process can be easily changed. In the above example, the inner ring groove grinder 72 _1, an inner ring inner diameter grinding machine 72 _2,
Mutual recombination between the outer ring groove grinder 72 ₃ can be performed freely. For this reason, for example, as shown in FIGS.
In the production line 71 _1, the configuration that places the inner ring inner diameter grinding machine 72 ₂ arranged on the process side after the inner ring groove grinder 72 _1, arranged two inner ring inner diameter grinding machine 72 ₂ as shown in FIG. 23 A line configuration can also be used. In this case, the inner diameter before grinding work supplies divided down to two inner ring inner diameter grinding machine 72 _2, it is possible to increase the production tact production line 71 _1. The inner ring inner diameter grinding is performed on another production line.

When the loading unit 82 is provided in the main body machine 75 of the common specification, the loading unit 82
Since the carry-in position I and the carry-out position O (FIGS. 18 and 19) are determined, even when the production equipment 72 is changed to another dedicated machine, the transfer device 73 ₂ (FIG. 17) has the same configuration. And the process can be changed more easily.

FIG. 24 is an explanatory diagram comparing the production equipment 72 as each grinding machine according to this embodiment with a conventional general grinding machine. FIGS. 7A to 7C show the outer ring groove grinder 72 ₃ and the inner ring inner diameter grinder 7 in this embodiment.
2 _2, and the inner ring groove grinder 72 ₁ respectively, and FIG. (D) ~ (F) shows conventional outer ring groove grinding machine, the inner ring inner diameter grinding machine, and the inner ring groove grinding machine, respectively. Each of the conventional dedicated machines has a separate design. However, in this embodiment, the basic style is unified by the common use of the main body machine 75, and the form can be easily changed. In addition, in each of the conventional dedicated machines, a cutting table 102 on which a headstock 101 is installed and a grinding wheel table 103 are separately provided. In this embodiment, a cutting table 81 having two steps is used to perform cutting. The table and grindstone unit are integrated to achieve compactness. In this embodiment, each spindle 7
9, 83A to 83C are built-in motor types, and the size of the equipment is reduced in combination with the use of the two-stage slide table 81.

It should be noted that the production equipment 72 dedicated to unit configuration
The jigs and tools such as the spindle chuck in the main body machine 75 of the common specification are interchangeable. Also, the jigs and tools in the modular unit 76 can be exchanged. Minor changes in products to be produced are dealt with by changing accessories such as jigs and tools.

FIG. 25 shows an example of a rolling bearing which is a product manufactured in the factory 4. This rolling bearing 100
A plurality of rolling elements 10 between the inner race 101 and the outer race 102
3 is interposed. The rolling element 103 includes the cage 10
4 is held. Seals 105 are provided on both sides of the bearing. When producing the rolling bearing 100 on the production line 71 shown in FIGS. 17 to 23, the inner ring groove grinder 72 ₁ in FIG. 18 performs grinding of the inner ring groove 101a of the inner ring 101,
The outer ring groove grinding machine 72 of FIG. _{20. 3,} the outer ring groove 1 of the outer ring 102
The grinding of 02a is performed.

FIG. 26 shows an example of a constant velocity joint which is another example of a product produced in the factory 4. In the constant velocity junction 200, a rolling element 203, which is a torque transmitting ball, is interposed between track grooves 201a and 202a along the axial direction of an inner ring 201 and an outer ring 202. The rolling elements 203 are held by a holder 204. Outer ring 202
Is open at one end, and the shaft 20 connected to the inner race 201 is
5 and a boot 206 is put on and sealed. Outer ring 2
The other end of 02 has a shaft portion 202b.

In the case of a mechanical component having the rolling elements 103 and 203 such as the rolling bearing 100 and the constant velocity joint 200, the exclusive use for each product or each product type group is required in terms of mass productivity, cost, accuracy, and the like. Production line is set up. Further, in the same factory 4, it may be required to produce a product that cannot be dealt with by a change in the setup, and in that case, the line is changed. Therefore, the virtual factory system 11 and the method of designing and operating the above factory equipment,
The adoption of the wide area factory production management system has a great effect of shortening the development time of line startup, optimizing production, and reducing production costs and shortening the delivery time due to production planning for allocating production to factories 4 in various places. In addition, in the case of bearings, the products produced in the factory 4 are, in addition to the above, wheel bearings (angular units, so-called second-generation, third-generation, or fourth-generation wheel bearings) and cylindrical roller bearings. Or tapered roller bearings. Further, the constant velocity joint may be a fixed joint or a sliding joint (including a tripole type).

[0074]

The virtual factory system according to the present invention is a system for verifying a factory in which a plurality of production facilities is a unit configuration dedicated machine in which modular units are interchangeably combined with a main machine having a common specification. , A virtual factory creation means for creating a virtual factory that is a data model of the factory,
Simulation means for causing the created virtual factory to perform simulated production to verify at least a production state and a distribution state, wherein the simulation means verifies the production state and the distribution state when the modular unit of the production equipment is replaced. It is possible to easily start a new production line for new products or product changes, change the process of the existing line, etc., and also to easily verify the entire factory, and to improve the efficiency of the production line. Development and development period can be shortened. A virtual factory / remote monitoring cooperation system according to the present invention includes a virtual factory system according to the present invention, a remote monitoring system that remotely monitors an actual factory corresponding to the virtual factory system, and a cooperative process between the virtual factory system and the remote monitoring system. Therefore, the verification result by the simulation can be effectively used, and the remote monitoring of the factory can be appropriately performed. The factory / verification system complex of the present invention is a factory / verification system complex composed of a real factory and a virtual factory system, wherein the real factory has a production line composed of production equipment and distribution equipment. Since a plurality of production facilities serving as line components are unit configuration dedicated machines in which modular units are interchangeably combined with a common main body machine, and the virtual factory system is the virtual factory system of the present invention. Thus, the development period of the factory can be shortened and production can be optimized.

[Brief description of the drawings]

FIG. 1 is an explanatory diagram of a conceptual configuration of a virtual factory system according to an embodiment of the present invention.

FIG. 2 is an explanatory diagram of a conceptual configuration of the virtual factory.

FIG. 3 is an explanatory diagram showing a conceptual configuration of a design operation / support system using the virtual factory system.

FIG. 4 is an explanatory diagram showing a conceptual configuration of a remote monitoring system.

FIG. 5 is an explanatory diagram of a configuration of a remote monitoring system.

FIG. 6 is an explanatory diagram of an example of an interactive screen in the remote monitoring system.

FIG. 7 is an explanatory diagram of a conceptual configuration of a virtual system / remote monitoring cooperation unit.

FIG. 8 is an explanatory diagram comparing screen examples of a virtual factory system and a remote monitoring system.

FIG. 9 is an explanatory diagram of an example of a layout display screen of the virtual factory system.

FIG. 10 is an explanatory diagram of an example of a production line display screen of the virtual factory system.

FIG. 11 is a process explanatory diagram showing the concept of a method of designing and operating factory equipment using the virtual factory system.

FIG. 12 is an explanatory diagram showing a concept of a communication relationship between a wide area factory production management system and its related elements.

FIG. 13 is an explanatory diagram of a conceptual configuration of a wide area factory production management system.

FIG. 14 is an explanatory diagram of a hardware configuration example of a wide area factory production management system.

FIG. 15 is a block diagram showing a conceptual configuration of production planning means;
FIG. 4 is an explanatory view of a production instruction.

FIG. 16 is an explanatory diagram of a layout example of a real factory.

FIG. 17 is an explanatory diagram of a layout portion in which production lines are arranged in a real factory.

FIG. 18 is a perspective view of a unit configuration dedicated machine in which production equipment in the production line is an inner ring groove grinder.

FIG. 19 is a perspective view of a unit construction dedicated machine in which the production facility is an inner ring inner diameter grinding machine.

FIG. 20 is a perspective view of a unit configuration dedicated machine using the production facility as an outer ring groove grinder.

FIG. 21 is an explanatory diagram of a main body machine of a common specification in the production facility.

FIG. 22 is a perspective view showing a part of the production line.

FIG. 23 is a perspective view showing a modified example of the production line.

FIG. 24 is a plan view showing each production facility of the production line in comparison with a conventional facility.

FIG. 25 is a cross-sectional view of a rolling bearing as an example of a product manufactured in the factory.

FIG. 26 is a sectional view of a constant velocity joint which is an example of a product produced in the factory.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Wide area factory production management system 2 ... Office 3 ... Communication network 4 ... Real factory 5 ... Sales office 6 ... Logistics office 7 ... Mobile terminal 8 ... Material dealer office 11 ... Virtual factory system 12 ... Integrated virtual factory system DESCRIPTION OF SYMBOLS 13 ... Integrated remote monitoring system 14 ... Order management system 15 ... Distribution management system 16 ... Production planning means 17 ... Equipment database 17A ... Equipment management database 18 ... Product database 19 ... Order management database 20 ... Distribution management database 21 ... Virtual factory 22: virtual factory creating means 23 ... simulation means 24 ... evaluation means 25 ... factory deployment support means 26 ... communication means 31, 32 ... virtual equipment 33 ... layout information 34, 35 ... equipment simulation part 36 ... whole simulation part 50 ... factory equipment Design and operation support system DESCRIPTION OF SYMBOLS 1 ... Remote monitoring system 52 ... Remote monitoring means 53 ... Monitoring result analysis means 54 ... Remote maintenance means 55 ... Remote driving means 56 ... Virtual factory / remote monitoring cooperation system 60, 61 ... Local area network 64 ... Virtual factory database 65 ... Operation Situation database 66 ... Cooperation means 67 ... Web server 68 ... Firewall 69 ... Router 71 ... Production line 72 ... Production equipment 73 ... Distribution equipment 75 ... Main machine 76 ... Modular unit 100 ... Rolling bearing 200 ... Constant velocity joint

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 3C100 AA05 AA22 AA42 AA43 AA59 BB02 BB13 BB17 BB19 BB31 BB33 BB36 CC11 5H223 AA05 DD07

Claims (11)

[Claims] 1. A system for verifying a factory, which is a dedicated machine for unit configuration, in which a plurality of production facilities are configured such that modular units are interchangeably combined with a main machine having a common specification. Virtual factory creating means for creating a factory, and simulation means for causing the created virtual factory to perform pseudo production to verify at least a production state and a logistics state, wherein the simulation means replaces a modular unit of a production facility. A virtual factory system that makes it possible to verify the production status and distribution status in the event of a failure. 2. A production line in which some of the production facilities are arranged side by side to form a production line. This is a test system for verifying a factory that is a unit dedicated to unit configuration in which modular units are interchangeably combined. The model is composed of information on the functions of each production facility and distribution facility in the factory and the layout of these facilities. Virtual factory creating means for creating a virtual factory; and simulation means for causing the created virtual factory to perform simulated production to verify the production status and the distribution status on the layout. A virtual factory system that can perform verification according to various changes in the production line including replacement of modular units 3. The virtual factory creating means is capable of creating models of various types of unit configuration-dedicated machines in which modular units are rearranged, based on information on main machines of production facilities and information on modular units registered in the facility database. The virtual factory system according to claim 1 or 2, wherein: 4. The virtual factory includes a plurality of virtual facilities that are models of individual facilities, wherein the simulation means includes a facility simulation unit that verifies each virtual facility;
The virtual factory system according to any one of claims 1 to 3, further comprising an overall simulation unit that integrates the verification results of the individual equipment simulation units and displays the result on a layout. 5. An equipment simulation section for a virtual equipment of a production equipment is capable of setting an adjustment condition and an operation condition that can be set for the production equipment, and is capable of performing verification according to the set adjustment condition and the operation condition. The virtual factory system according to claim 4. 6. A virtual factory system according to claim 1, a remote monitoring system for remotely monitoring a real factory corresponding to the virtual factory system, and a virtual factory system and a remote monitoring system. A virtual factory / remote monitoring coordination system comprising a coordination means for performing coordination processing. 7. The virtual factory / remote monitoring cooperation system according to claim 6, wherein the remote monitoring system is capable of remote maintenance. 8. The remote monitoring system is capable of performing remote monitoring and remote maintenance interactively. The remote monitoring system includes an image of equipment to be monitored, an image of an operator on a factory side, and an image on a same screen of a display device. 8. The virtual factory / remote monitoring cooperative system according to claim 7, wherein character information used for monitoring or remote maintenance can be displayed side by side, and voice can be transmitted. 9. The virtual factory system according to claim 1, wherein in the factory, a product to be produced is a mechanical part having rolling elements. 10. The virtual factory / remote monitoring cooperative system according to claim 6, wherein the factory is a machine component whose product to be produced is a mechanical part having a rolling element. 11. A factory / verification system complex comprising a real factory and a virtual factory system, wherein the real factory has a production line composed of a production facility and a logistics facility. A plurality of production facilities are unit-structure-dedicated machines in which modular units are interchangeably combined with a common main machine, and the virtual factory system is a virtual machine according to any one of claims 1 to 5. A factory / verification system complex that is a factory system.