JP2024129496A - Production instruction system - Google Patents

Abstract

[Problem] To provide a production instruction system that can easily set IP addresses for production equipment. [Solution] A production instruction system for producing multiple types of products comprises multiple production equipment 50 for producing multiple types of products, and a server device 40 that can communicate with each of the multiple production equipment via Ethernet. The multiple production equipment stores information on MAC addresses assigned in advance, and has an equipment control unit 51a that transmits information on its own MAC address stored to the server device. The server device stores address information, and upon receiving MAC address information from a specific equipment control unit of a specific production equipment among the multiple production equipment, sets the IP address of the specific equipment control unit based on the address information. [Selected Figure] Figure 1

Description

This disclosure relates to a production instruction system.

Conventionally, a manufacturing system has been known that includes a number of unit cells that automatically perform operations on a workpiece, a connection mechanism that connects the unit cells together, and a management device that manages the unit cells (see, for example, Patent Document 1).

In this manufacturing system, a production line is made up of an array of multiple unit cells that are individually and collectively managed by a management device. The manufacturing system is configured so that each time a part or semi-finished product passes through each of the multiple unit cells, a unit operation such as processing or sorting is performed on the workpiece, and a product is manufactured. The multiple unit cells are each provided so that the entrance of any one unit cell and the exit of any other unit cell are adjacent to each other, allowing any unit cells to be combined together.

JP 2020-151770 A

Incidentally, as an example of a system in which a management device manages multiple unit cells, such as the manufacturing system described in Patent Document 1, there is a production instruction system in which multiple pieces of production equipment each communicate with a server using a communication protocol such as TCP/IP. In such a production instruction system, in order to enable communication between the server and the multiple pieces of production equipment, it is necessary to set a different IP address for each piece of production equipment in advance.

IP address configuration work is generally performed by workers with specialized knowledge. However, if IP address configuration work can only be performed by workers with specialized knowledge, inconveniences arise, such as the inability to easily replace production equipment.

The purpose of this disclosure is to provide a production instruction system that can easily set the IP address of production equipment.

The invention described in claim 1 is
A production instruction system for producing a plurality of types of products,
A plurality of production facilities (50) for producing a plurality of types of products;
A server device (40) capable of communicating with each of the plurality of production facilities via Ethernet;
Each of the production equipment has an equipment control unit (51 a) that stores information on a MAC address that is assigned in advance and transmits the stored information on its own MAC address to the server device,
The server device stores address information linking multiple production equipment corresponding to each of multiple types of products, MAC address information pre-assigned to each equipment control unit, and IP address information that can be set in the equipment control unit, and when it receives MAC address information from a specific equipment control unit possessed by a specific production equipment among the multiple production equipment, it sets the IP address of the specific equipment control unit based on the address information.

This allows the production instruction system to easily set different IP addresses for the equipment control units of multiple production equipment without the need for an expert.

The reference symbols in parentheses attached to each component indicate an example of the correspondence between the component and the specific components described in the embodiments described below.

1 is a schematic configuration diagram of a production instruction system according to the present disclosure. 4A and 4B are diagrams illustrating an example of registered contents of a model registration database and a module registration database. FIG. 4 is a diagram showing an example of registered contents of a layout registration database. FIG. 11 is a diagram illustrating an example of a control process executed by a production management server. FIG. 4 is a diagram illustrating an example of a control process executed by an integrated CPU unit. FIG. 11 illustrates an example of a control process executed by a BOOTP server. FIG. 2 is a diagram illustrating an example of a control process executed by an equipment CPU unit. 13 is a diagram showing the state in which IP addresses are set when an equipment CPU unit is replaced. FIG.

One embodiment of the production instruction system 1 of the present disclosure will be described with reference to Figs. 1 to 8. As shown in Fig. 1, the production instruction system 1 of the present disclosure includes an equipment management server 10, a production management server 20, an integrated control unit 30, a BOOTP server 40, and a plurality of equipment modules 50. The components 10, 20, 30, 40, and 50 that make up the production instruction system 1 are connected to each other via a communication network 5, and are configured to be able to communicate with each other via Ethernet. Specifically, the components 10, 20, 30, 40, and 50 that make up the production instruction system 1 are configured to be able to communicate with each other using the TCP/IP protocol. TCP/IP is an abbreviation for Transmission Control Protocol/Internet Protocol.

The equipment management server 10 is a server device that manages the production management server 20, the integrated control unit 30, and the multiple equipment modules 50 that constitute the production instruction system 1. The equipment management server 10 is a computer that has a communication unit, a display unit, a volatile storage medium, a non-volatile storage medium, a calculation unit, etc., which are not shown.

The communication unit of the equipment management server 10 is a network interface for connecting to the communication network 5 and communicating with other devices via the communication network 5. The display unit of the equipment management server 10 is a display device that displays to the user the operating status and operation status of the production management server 20, the integrated control unit 30, and the multiple equipment modules 50 that are managed by the equipment management server 10.

The calculation unit of the facility management server 10 executes a program stored in a non-volatile storage medium to execute predetermined processing. During execution, data is written to the volatile storage medium and the non-volatile storage medium as necessary, data is read from the volatile storage medium and the non-volatile storage medium, and communication is performed with other devices using the communication unit. The volatile storage medium and the non-volatile storage medium are configured as non-transient physical storage media. The facility management server 10 of this embodiment is configured as a cloud server created in a cloud environment.

The production management server 20 is a server device that manages information necessary to produce products using multiple equipment modules 50. The production management server 20 is a computer that has a communication unit, a display unit, input devices such as a keyboard and a mouse, a volatile storage medium, a non-volatile storage medium, a calculation unit, etc. (not shown).

The communication unit of the production management server 20 is a network interface for connecting to the communication network 5 and communicating with other devices via the communication network 5. The display unit of the production management server 20 is a display device that displays to the user various information necessary for the production of products managed by the production management server 20. This display unit displays data and the like that is input by workers operating input devices such as a keyboard and mouse.

The calculation unit of the production management server 20 executes predetermined processing by executing a program stored in a non-volatile storage medium. During execution, the calculation unit writes data to the volatile storage medium and the non-volatile storage medium as necessary, reads data from the volatile storage medium and the non-volatile storage medium, and communicates with other devices using the communication unit.

The non-volatile storage medium of the production management server 20 stores various information necessary for producing products. Specifically, as shown in FIG. 2, the non-volatile storage medium of the production management server 20 has a model registration database 21 in which information on the equipment modules 50 necessary for producing a specified product is registered in advance. The non-volatile storage medium of the production management server 20 also has a module registration database 22 in which detailed information on the equipment modules 50 that can be connected to the production instruction system 1 is registered in advance. The volatile storage medium and the non-volatile storage medium are composed of non-transitive physical storage media. Hereinafter, the model registration database 21 is also referred to as model registration DB 21. The module registration database 22 is also referred to as module registration DB 22.

In the production instruction system 1 disclosed herein, a production line for producing a product is configured by combining multiple equipment modules 50. The production line is then configured to produce the product. Furthermore, the production instruction system 1 is configured to be capable of producing multiple types of product models depending on the configuration of the production line.

The products produced by a production line combining multiple equipment modules 50 are produced through multiple processes performed by each of the multiple equipment modules 50. That is, the products produced by the production instruction system 1 of the present disclosure are produced by work performed in each process of the multiple equipment modules 50. In other words, the products are produced by the equipment modules 50 that are arranged in a predetermined process order in multiple processes. For this reason, the multiple equipment modules 50 are arranged in the order of the processes that will be performed to produce the product.

The tasks required to produce a product differ depending on the type of product. For this reason, a production line configured by combining multiple equipment modules 50 has a different configuration depending on the product being produced. Specifically, the tasks, quantities, and order of operations performed by the equipment modules 50 differ depending on the product being produced.

Therefore, the model registration DB 21 registers information on the multiple equipment modules 50 that make up the production line for each model of product produced by the production line. Specifically, as shown in FIG. 2, the model registration DB 21 registers, for each model of product, information on the production part number and information on the sequence of process types required to produce the product. Here, the process type is the type of work performed in the equipment module 50. For example, process types include an "input process" for inputting the workpiece, an "application process" for applying chemicals, an "assembly process" for assembling parts, an "image inspection process" for performing image inspection, a "recovery process" for recovering the workpiece, and a "screw tightening process" for tightening screws.

Furthermore, it is possible to register multiple processes for one process type. For example, for the "input process," it is possible to register multiple "input processes," such as "input process A" and "input process B," depending on the type of work to be input.

In the model registration DB21, information on the production part number and information on the sequence of process types are linked and registered for each product model. In this disclosure, the model registration DB21 is configured to be able to register 100 types of product models.

In addition, in the present disclosure, a product can be produced using a maximum of 10 process types. For this reason, a production line for producing a product is configured by arranging a maximum of 10 equipment modules 50 for performing 10 different process types in a predetermined process order. In other words, in the present disclosure, a maximum of 10 equipment modules 50 are arranged adjacent to each other in the process order, and a product is produced by a production line configured of the arranged maximum of 10 equipment modules 50.

Hereinafter, among the positions of the equipment modules 50 arranged in the order of processes, the position of the first process will be referred to as the first module position. Then, in order from the first module position to the last process, the positions will be referred to as the second module position, third module position, fourth module position, fifth module position, sixth module position, seventh module position, eighth module position, ninth module position, and tenth module position.

Note that "NULL" in the model registration DB 21 shown in FIG. 2 indicates a process where no work is required, and indicates a module position where installation of an equipment module 50 is not required. For example, the number of processes required to produce a product with production number "X" is three, and installation of an equipment module 50 is not required in the fourth to tenth module positions.

The number of equipment modules 50 that make up the production line is not limited, and the maximum number may be less than 10 units or more than 10 units. Furthermore, the number of product models that can be registered in the model registration DB 21 is not limited, and may be less than 100 types or more than 100 types.

The module registration DB 22 stores information about each equipment module 50 that can be connected to the production instruction system 1 of the present disclosure. Specifically, as shown in FIG. 2, the module registration DB 22 stores, for each equipment module 50, information about the registration name, executable process type, and MAC address information that is assigned in advance to the equipment PLC unit 51 (described later) provided in the equipment module 50. Furthermore, the module registration DB 22 stores information about whether the equipment module 50 is in use. In this manner, the module registration DB 22 stores the registration name information, process information, MAC address information that is assigned in advance to the equipment PLC unit 51 of the equipment module 50, and the usage status, linked to each other. Hereinafter, the MAC address information that is assigned in advance to the equipment PLC unit 51 of the equipment module 50 may be simply referred to as the MAC address information of the equipment module 50.

Moreover, multiple equipment modules 50 capable of executing the same process can be registered in the module registration DB 22. For example, as shown in FIG. 2, information on two equipment modules 50, module number 1 and module number 253, can be registered as equipment modules 50 capable of executing the same "input process B." This indicates that the equipment module 50 executing "input process B" can be either the equipment module 50 with module number 1 or the equipment module 50 with module number 253.

The non-volatile storage medium of the production management server 20 stores process information that combines the model registration DB 21 and module registration DB 22. The process information includes information on the registered names and MAC addresses of the available equipment modules 50 that are assigned to the first through tenth module positions to produce a specific product from among multiple types of products.

For example, in the example shown in FIG. 2, as process information for producing production item number "X", the first module position is assigned MAC address information of an equipment module 50 that can execute "insertion process A" and is in a usable state. The second module position is assigned MAC address information of an equipment module 50 that can execute "insertion process B" and is in a usable state. The third module position is assigned MAC address information of an equipment module 50 that can execute "recovery process A" and is in a usable state. Furthermore, the fourth to tenth module positions are assigned "NULL" information, which indicates processes that do not require work.

In this way, the production management server 20 stores information on multiple equipment modules 50 corresponding to multiple types of products, information on the process order of the multiple equipment modules 50, and information on the MAC addresses of each of the multiple equipment modules 50, all of which are linked together. The information stored in the equipment modules 50 can be registered by a user operating an input device of the production management server 20. Hereinafter, the information stored in the model registration DB 21 and module registration DB 22 of the production management server 20 may be referred to as module information.

The non-volatile storage medium of the production management server 20 also stores information on processing recipes indicating the control contents of the equipment modules 50 corresponding to the process types registered in the model registration DB 21 and the module registration DB 22. The processing recipes are programs executed by the equipment PLC unit 51 provided in the equipment modules 50, and are predetermined according to the model and process of the product to be produced. The processing recipes are execution programs installed in the equipment PLC unit 51 of each of the multiple equipment modules 50 arranged to produce a specific product. The processing recipes can be registered in the non-volatile storage medium, for example, by the user operating an input device. In the following, the processing executed by the calculation unit of the production management server 20 will be described simply as processing executed by the production management server 20.

Returning to FIG. 1, the integrated control unit 30 is a control device that collectively manages the multiple equipment modules 50 that make up a production line that produces a specific product. In other words, the integrated control unit 30 manages the multiple equipment modules 50 that are arranged on the same network. As shown in FIG. 1, the integrated control unit 30 has an integrated PLC unit 31 and an integrated relay device 32.

The integrated PLC unit 31 is a programmable logic controller that is configured by combining multiple units with different functions. Specifically, the integrated PLC unit 31 is configured by combining one integrated CPU unit 31a, two integrated IF units 31b, and an I/O unit (not shown).

The integrated CPU unit 31a is composed of a microcomputer including a CPU, ROM, RAM, and other memories, and its peripheral circuits. The memory is composed of a non-transient tangible storage medium. The integrated CPU unit 31a performs various calculations and processing based on the programs stored in the ROM.

Specifically, the integrated CPU unit 31a is connected so that it can transmit information such as the operating state and operation status of each of the multiple equipment modules 50 to the equipment management server 10. The integrated CPU unit 31a is also connected so that it can receive module information and process information from the production management server 20. The integrated CPU unit 31a is connected to the BOOTP server 40 via the integrated relay device 32, and is capable of transmitting process information received from the production management server 20 to the BOOTP server 40.

The two integrated IF units 31b are network interfaces for connecting to the communication network 5 and communicating with other devices via the communication network 5. One of the two integrated IF units 31b is connected to the facility management server 10 via the communication network 5, and the other is connected to the production management server 20 via the communication network 5. As a result, the integrated control unit 30 is connected to be able to communicate with the facility management server 10 and the production management server 20.

The I/O unit is an interface that connects to an input/output device (not shown) and communicates with the input/output device. Examples of input/output devices that can be connected to the I/O unit include a display device, a sensor, a buzzer, and a lamp.

The integrated relay device 32 is a relay provided between other devices when connecting other devices to each other via the communication network 5. The integrated relay device 32 is connected to the integrated CPU unit 31a and the BOOTP server 40. The integrated relay device 32 connects the integrated CPU unit 31a and the BOOTP server 40 so that they can communicate with each other.

The integrated relay device 32 is also connected to an equipment relay device 52 provided in the equipment module 50. The integrated relay device 32 connects the integrated CPU unit 31a and the equipment PLC section 51 via the equipment relay device 52 so that they can communicate with each other, and also connects the equipment PLC section 51 and the BOOTP server 40 so that they can communicate with each other. For example, a switching hub can be used as the integrated relay device 32.

The BOOTP server 40 sets the IP address of the requested equipment CPU unit 51a in response to a request from the equipment CPU unit 51a provided in the equipment module 50. The BOOTP server 40 is a computer having a communication unit, a display unit, a volatile storage medium, a non-volatile storage medium, a calculation unit, etc. (not shown). The communication unit of the BOOTP server 40 is a network interface for connecting to the communication network 5 and communicating with other devices via the communication network 5. The display unit of the BOOTP server 40 is a display device that displays information about the equipment module 50 that constitutes the production line to the user. The calculation unit of the BOOTP server 40 executes a program stored in the non-volatile storage medium to execute a predetermined process. During the execution, data is written to the volatile storage medium and the non-volatile storage medium as necessary, data is read from the volatile storage medium and the non-volatile storage medium, and the calculation unit is used to communicate with other devices.

The non-volatile storage medium of the BOOTP server 40 also stores various information required to set the IP address of the equipment CPU unit 51a. Specifically, the non-volatile storage medium has a layout registration database 41 in which information on the process sequence of the equipment modules 50 corresponding to each of multiple types of products, and information on the IP address and MAC address set in the equipment CPU unit 51a are registered. Hereinafter, the layout registration database 41 is also referred to as the layout registration DB 41.

As shown in FIG. 3, the layout registration DB 41 stores information on the first to tenth module positions, which indicate the process order of each of the equipment modules 50 that make up a production line that produces a specific product from among multiple types of products. The layout registration DB 41 also stores information on the first to tenth module positions, which are linked to IP address information registered in the equipment CPU unit 51a installed in the equipment module 50.

As an example of the present disclosure, the IP address of the equipment module 50 located at the first module position is specified as "192.168.0.1". The IP address of the equipment module 50 located at the second module position is specified as "192.168.0.2". The IP address of the equipment module 50 located at the third module position is specified as "192.168.0.3". The IP address of the equipment module 50 located at the fourth module position is specified as "192.168.0.4". The IP address of the equipment module 50 located at the fifth module position is specified as "192.168.0.5". The IP address of the equipment module 50 located at the sixth module position is specified as "192.168.0.6". The IP address of the equipment module 50 located at the seventh module position is specified as "192.168.0.7". The IP address of the equipment module 50 located in the eighth module position is specified as "192.168.0.8". The IP address of the equipment module 50 located in the ninth module position is specified as "192.168.0.9". The IP address of the equipment module 50 located in the tenth module position is specified as "192.168.0.10". Note that the IP addresses specified for the first to tenth module positions are not limited to "192.168.0.1" to "192.168.0.10", and any IP addresses that are different from each other can be specified.

In addition, the layout registration DB 41 is capable of registering information on the equipment modules 50 placed at each of the first through tenth module positions. Specifically, the layout registration DB 41 is capable of registering information on the module numbers of the equipment modules 50 at each of the first through tenth module positions, and information on the MAC addresses registered in the equipment CPU units 51a of the equipment modules 50. As a result, the MAC addresses of the equipment CPU units 51a provided in the equipment modules 50 placed at each of the first through tenth module positions are linked to and registered with information on the IP addresses set in the equipment CPU units 51a.

In this way, the layout registration DB 41 stores linked information on the process order of each of the equipment modules 50 corresponding to each of the multiple types of products, module number information, equipment module 50 MAC address information, and IP address information. Hereinafter, the linked and registered information on the process order of each of the equipment modules 50 corresponding to each of the multiple types of products, module number information, equipment module 50 MAC address information, and IP address information will also be referred to as address information.

In response to a request from the equipment PLC unit 51 connected via the integrated relay device 32, the BOOTP server 40 sets the IP address linked to the MAC address of the equipment CPU unit 51a in the layout registration DB 41 to the equipment CPU unit 51a. When the BOOTP server 40 receives information on the MAC address of the equipment PLC unit 51 from the equipment PLC unit 51, the BOOTP server 40 registers the IP address in the layout registration DB 41 and assigns the IP address linked to the MAC address to the equipment CPU unit 51a of the equipment PLC unit 51. The non-volatile storage medium of the BOOTP server 40 functions as an address storage unit. The calculation unit of the BOOTP server 40 functions as an IP setting unit.

Note that the volatile storage medium and the non-volatile storage medium are non-transient tangible storage media. Also, BOOTP is an abbreviation for BOOT strap protocol. In the following, the processing executed by the calculation unit of the BOOTP server 40 will be described simply as processing executed by the BOOTP server 40.

The equipment modules 50 are production equipment that produce products by performing preset operations in a specific process when producing the product. As shown in FIG. 1, in the production instruction system 1 of the present disclosure, multiple equipment modules 50 are arranged next to each other according to the model of the product to be produced. The type and number of the equipment modules 50 to be arranged are registered in advance in the model registration DB 21 of the production management server 20 according to the model of the product to be produced. The multiple equipment modules 50 arranged according to the model of the product make up one production line. The multiple equipment modules 50 that make up the production line are each connected to a communication network 5.

The multiple equipment modules 50 that make up the production line each perform different tasks that are preset for each product being produced. Each of the multiple equipment modules 50 is equipped with various devices for performing the tasks that it performs.

However, the main equipment provided in the multiple equipment modules 50 is similar, as shown in FIG. 1. For this reason, of the multiple equipment modules 50, only the equipment module 50 that is directly connected to the integrated relay device 32 shown in FIG. 1 will be described in detail, and detailed descriptions of the other equipment modules 50 will be omitted.

The equipment module 50 has an equipment PLC section 51, an equipment relay device 52, and a QR code (registered trademark) reader 53. The equipment PLC section 51 is configured by combining multiple units having different functions. Specifically, the equipment PLC section 51 is configured by combining one equipment CPU unit 51a, one equipment IF unit 51b, and an I/O unit (not shown).

The equipment CPU unit 51a is composed of a microcomputer including a CPU, ROM, RAM, and other memories, and its peripheral circuits. The memory is composed of a non-transient tangible storage medium. The equipment CPU unit 51a performs various calculations and processing based on programs stored in the ROM. Specifically, when producing a product, the equipment CPU unit 51a operates the devices provided in each equipment module 50 by performing various calculations and processing based on processing recipes previously stored in the ROM in order to execute work that is previously set for each equipment module 50.

The equipment CPU unit 51a is assigned a unique MAC address in advance. In addition, a document is attached to the equipment module 50 that displays information about the MAC address that is set in the equipment CPU unit 51a installed in the equipment module 50 itself. The equipment CPU unit 51a can be set to any IP address by a control signal sent from the BOOTP server 40. The equipment CPU unit 51a functions as an equipment control unit.

The equipment IF unit 51b is a network interface for communication between the equipment CPU unit 51a and the QR code reader 53. The QR code reader 53 is connected to the equipment IF unit 51b.

The I/O unit is an interface that connects to an input/output device (not shown) and communicates with the input/output device. Examples of input/output devices that can be connected to the I/O unit include a display device, a sensor, a buzzer, and a lamp.

The equipment relay device 52 is a relay provided between other devices when connecting other devices to each other via the communication network 5. The integrated relay device 32 and the equipment CPU unit 51a are connected to the equipment relay device 52. The equipment relay device 52 connects the integrated relay device 32 and the equipment CPU unit 51a so that they can communicate with each other. In other words, the equipment relay device 52 connects the integrated CPU unit 31a and the BOOTP server 40 connected to the integrated relay device 32 to the equipment CPU unit 51a so that they can communicate with each other.

The equipment relay device 52 is further connected to equipment relay devices 52 installed in other equipment modules 50 different from the equipment module 50 in which it is installed. As a result, the other equipment modules 50 are connected to the integrated CPU unit 31a and the BOOTP server 40 connected to the integrated relay device 32. As a result, all equipment modules 50 that make up the production line are connected to the integrated CPU unit 31a and the BOOTP server 40. As the equipment relay device 52, for example, a switching hub can be used.

The QR code reader 53 is a device that reads information written in a QR code and outputs the read information. In this embodiment, the QR code reader 53 is used to read the QR code of a document attached to an equipment module 50 that is placed next to the equipment module 50 in which the QR code reader 53 is installed.

The QR code reader 53 reads the QR code of the equipment module 50 placed next to it, thereby reading the MAC address information registered in the equipment CPU unit 51a installed in the equipment module 50 placed next to it. In this disclosure, the QR code reader 53 is attached to the right side of the equipment module 50 in which it is placed, and is capable of reading the MAC address information registered in the equipment CPU unit 51a of the equipment module 50 placed to the right.

The MAC address information read by the QR code reader 53 is sent to the equipment CPU unit 51a and can be sent to the BOOTP server 40 via the equipment CPU unit 51a. The QR code reader 53 is attached at a position corresponding to the position where the QR code is attached on the equipment module 50 located on the right side. The QR code reader 53 functions as an address detection unit.

In a production instruction system 1 equipped with such various components, the combination and process order of the equipment modules 50 that make up the production line are set according to the product to be produced. After installing the multiple equipment modules 50 in the set combination and process order, it is necessary to make the equipment CPU unit 51a provided in each of the multiple equipment modules 50 capable of communicating with other equipment. For this reason, it is necessary to set different IP addresses for the equipment CPU unit 51a of each equipment module 50.

If the IP address configuration work can only be done by an expert with specialized knowledge, an expert is required every time an equipment module 50 is installed. This can cause problems such as the equipment module 50 not being able to be installed without an expert, or the equipment module 50 not being able to be replaced when the equipment CPU unit 51a breaks down.

In contrast, the production instruction system 1 disclosed herein can set different IP addresses to the equipment CPU units 51a of the equipment modules 50 without the need for an expert. Below, the operation of the production instruction system 1 disclosed herein when setting IP addresses to the equipment CPU units 51a when installing the equipment modules 50 in the set combination and process order will be described with reference to the control processing shown in Figures 4 to 7. In this disclosure, an example will be described in which the production part number of the product to be produced is "Y" and a production line is set up to produce production part number "Y".

Let us assume that a user inputs information about the production number of the product to be produced, which is "Y", and information about the production quantity, to the production management server 20 in order to produce a product with production number "Y". Then, as shown in FIG. 4, in step S100, the production management server 20 creates process information based on the module information. Specifically, the production management server 20 creates the process information by assigning an equipment module 50 to each of the first module position to the fifth module position for production number "Y" registered in the model registration DB 21. Of the equipment modules 50 registered in the module registration DB 22, an equipment module 50 that is in a usable state is assigned to each of the first module position to the fifth module position.

In the example of the present disclosure, as shown in FIG. 3, the first module position is assigned information on an equipment module 50 with module number 1 as process information for producing production item number "Y". Specifically, the first module position is assigned information on an equipment module 50 with a registration name of "Baby Turtle Insert 01" and a MAC address of "00000AD75DFB". The second module position is assigned information on an equipment module 50 with module number 253. Specifically, the second module position is assigned information on an equipment module 50 with a registration name of "Input 15" and a MAC address of "00000AD75EEB".

In addition, the third module position is assigned information about an equipment module 50 with module number 10. Specifically, the third module position is assigned information about an equipment module 50 with a registration name of "Application03" and a MAC address of "00000AD75E5C". In addition, the fourth module position is assigned information about an equipment module 50 with module number 15. Specifically, the fourth module position is assigned information about an equipment module 50 with a registration name of "Image Inspection02" and a MAC address of "00000AD75F4B".

In addition, the fifth module position is assigned information about an equipment module 50 with module number 3. Specifically, the fifth module position is assigned information about an equipment module 50 with a registration name of "Recovery 01" and a MAC address of "00000AD75D6B." The sixth to tenth module positions are then assigned information about "NULL," which indicates processes that do not require work.

Then, in step S110, the production management server 20 transmits module information and process information to the integrated CPU unit 31a of the integrated control unit 30. Specifically, the production management server 20 transmits various information on the five equipment modules 50 required to produce production item number "Y" registered in the model registration DB 21 and the module registration DB 22, and information on the process order of each of the five equipment modules 50. Then, in step S120, the production management server 20 waits until it receives a request signal from the integrated CPU unit 31a for a processing recipe to be installed in each of the equipment modules 50.

When the integrated CPU unit 31a receives the module information and process information in step S200 as shown in FIG. 5, the display device displays the module information and process information in step S210. Specifically, the display device of the integrated control unit 30 displays the registration names and process order information of the five equipment modules 50 required to produce production item number "Y". In this way, the integrated control unit 30 notifies the user of the registration names and process order information of each of the five equipment modules 50 required to produce production item number "Y".

The user can check the registered names and process order information of the five equipment modules 50 displayed on the display device of the integrated control unit 30, and install the five equipment modules 50 in the displayed process order.

In addition, in step S220, the integrated CPU unit 31a transmits process information to the BOOTP server 40. Specifically, the integrated CPU unit 31a transmits information on the process order of the five equipment modules 50 required to produce production item number "Y" and information on the MAC addresses of each of the five equipment modules 50 to the BOOTP server 40. Then, in step S230, the integrated CPU unit 31a waits until it receives information on the IP addresses set in each of the five equipment modules 50 from the BOOTP server 40.

As shown in FIG. 6, when the BOOTP server 40 receives the process information in step S300, it updates the address information registered in the layout registration DB 41 in step S310. Specifically, the BOOTP server 40 registers the IP address information registered in the equipment CPU units 51a of the five equipment modules 50 in the first module position to the fifth module position by linking it to the MAC address information of each of the five equipment modules 50.

In the present disclosure, the MAC address information of the equipment module 50 with module number 1 assigned to the first module position in the process information is linked to the IP address information of "192.168.0.1" and registered in the layout registration DB 41. The MAC address information of the equipment module 50 with module number 253 assigned to the second module position is linked to the IP address information of "192.168.0.2" and registered in the layout registration DB 41. The MAC address information of the equipment module 50 with module number 10 assigned to the third module position is linked to the IP address information of "192.168.0.3" and registered in the layout registration DB 41. The MAC address information of the equipment module 50 with module number 15 assigned to the fourth module position is linked to the IP address information of "192.168.0.4" and registered in the layout registration DB 41. Additionally, the MAC address information of the equipment module 50 with module number 3 assigned to the fifth module position is linked to the IP address information of "192.168.0.5" and registered in the layout registration DB 41.

Then, in step S320, the BOOTP server 40 waits until it receives MAC address information from each of the equipment CPU units 51a of the five equipment modules 50 registered in the layout registration DB 41.

Next, the operation performed by the equipment CPU unit 51a of the equipment PLC section 51 provided in the five equipment modules 50 installed by the user in the process order will be described with reference to FIG. 7. Note that since the operations performed by each of the equipment CPU units 51a of the five equipment modules 50 are similar, only the operation performed by one equipment CPU unit 51a will be described. When the power is turned on after the equipment modules 50 are installed, the equipment CPU unit 51a executes the control process shown in FIG. 7.

First, in step S400, the equipment CPU unit 51a determines whether the startup is an initial startup. In other words, the equipment CPU unit 51a determines whether the power has been turned on for the first time since it was installed in the process order.

If it is not determined that the startup is an initial startup, the equipment CPU unit 51a skips all processing from step S410 onwards. In contrast, if it is determined that the startup is an initial startup, in step S410, the equipment CPU unit 51a requests the BOOTP server 40 to set an IP address for itself by sending information about its own MAC address to the BOOTP server 40. Then, in step S420, the equipment CPU unit 51a waits until an IP address is set for itself by the BOOTP server 40.

When the BOOTP server 40 determines in step S320 that it has received MAC address information from the equipment CPU unit 51a of the equipment module 50, it proceeds to processing in step S330. In step S330, the BOOTP server 40 compares the MAC address information registered in the address information of the layout registration DB 41 with the MAC address information received from the equipment CPU unit 51a.

Then, in step S340, the BOOTP server 40 sets the IP address of the equipment module 50 whose MAC address matches the received MAC address among the equipment modules 50 registered in the address information. The BOOTP server 40 sets the IP address linked to the MAC address that matches the received MAC address in the equipment CPU unit 51a that sent that MAC address. In other words, when the BOOTP server 40 receives information on the MAC address assigned to the equipment CPU unit 51a sent from the equipment CPU unit 51a, it sets the IP address of this equipment CPU unit 51a based on the address information.

As a result, an IP address is set for each initially started equipment CPU unit 51a. In this way, the production instruction system 1 disclosed herein can set different IP addresses for the equipment CPU units 51a of each equipment module 50 even without the need for an expert.

Then, in step S350, the information on the set IP address is linked to the MAC address information of the equipment CPU unit 51a in which the IP address is set and transmitted to the integrated CPU unit 31a.

Returning to FIG. 7, if the equipment CPU unit 51a determines in step S420 that an IP address has been set for itself by the BOOTP server 40, it proceeds to processing in step S430. In step S430, the equipment CPU unit 51a obtains, via the QR code reader 53, the MAC address information of the equipment module 50 located next to the equipment module 50 in which the equipment CPU unit 51a is installed. The equipment CPU unit 51a obtains, via the QR code reader 53, the MAC address information of the equipment module 50 located to the right of the equipment module 50 in which the equipment CPU unit 51a is installed, by using the QR code reader 53 to obtain the QR code of a document attached to the equipment module 50 located to the right.

In step S440, the equipment CPU unit 51a transmits the MAC address information of the equipment module 50 located to its right to the integrated CPU unit 31a.

Of the five equipment modules 50 installed in process order, the QR code reader 53 installed in the equipment module 50 located at the far right cannot obtain the MAC address information of the equipment module 50. This is because there is no equipment module 50 to the right of the equipment module 50 located at the far right, and there is no readable QR code in the position corresponding to the position where the QR code reader 53 is installed.

In this case, in step S440, the equipment CPU unit 51a installed in the equipment module 50 located at the far right transmits information to the integrated CPU unit 31a that the equipment module 50 in which it is installed is the far right.

Then, in step S450, the equipment CPU unit 51a waits until it receives processing recipe information from the integrated CPU unit 31a.

Returning to FIG. 5, when the integrated CPU unit 31a receives information on the IP addresses set for each of the five equipment modules 50 from the BOOTP server 40 in step S230, it proceeds to processing in step S240. In step S240, the integrated CPU unit 31a determines whether the placement of the equipment modules 50 is correct based on the MAC address information received from the equipment CPU unit 51a.

Specifically, the integrated CPU unit 31a acquires information on the arrangement of the five equipment modules 50 based on the MAC address information received from the equipment CPU unit 51a of each of the five equipment modules 50. Then, the integrated CPU unit 31a compares the acquired arrangement of the five equipment modules 50 with the arrangement order contained in the address information to determine whether the arrangement of the five equipment modules 50 is correct. In other words, the integrated CPU unit 31a determines whether the five equipment modules 50 are arranged in process order based on the MAC address information and address information transmitted from the QR code reader 53 of each of the five equipment modules 50. The integrated CPU unit 31a functions as an arrangement determination unit.

If it is not determined that the placement of the equipment module 50 is correct, in step S250, the integrated CPU unit 31a outputs an error indicating that the placement of the equipment module 50 is incorrect. The error output may be displayed on the display device of the integrated control unit 30, or may be output by a buzzer, lamp, or the like connected to the I/O unit of the integrated control unit 30. The error output may also be output to the equipment management server 10. When the equipment management server 10 receives an error output signal from the integrated CPU unit 31a, it may display on the display device of the equipment management server 10 that the placement of the equipment module 50 is incorrect.

If it is determined that the placement of the equipment modules 50 is correct, in step S260, the integrated CPU unit 31a requests the production management server 20 for information on the processing recipe to be installed in each of the equipment CPU units 51a of the five equipment modules 50. Then, in step S270, the integrated CPU unit 31a waits until it receives the processing recipe information from the production management server 20.

Returning to FIG. 4, when the production management server 20 receives a processing recipe request signal from the integrated CPU unit 31a in step S120, it proceeds to processing in step S130. In step S130, the production management server 20 transmits processing recipe information corresponding to each of the five equipment modules 50 to the integrated CPU unit 31a. Specifically, the production management server 20 transmits processing recipe information for causing the equipment modules 50 to execute each of the tasks of "input process A", "input process B", "coating process C", "image inspection process B", and "recovery process A" to the integrated CPU unit 31a.

When the integrated CPU unit 31a receives the processing recipe information from the production management server 20 in step S270, the integrated CPU unit 31a proceeds to processing in step S280. In step S280, the integrated CPU unit 31a transmits the processing recipe information received from the production management server 20 to the equipment CPU units 51a provided in each of the corresponding equipment modules 50.

Specifically, the integrated CPU unit 31a transmits information on a processing recipe for performing the work of the "input process A" to the equipment CPU unit 51a of the equipment module 50 with module number 1. The integrated CPU unit 31a also transmits information on a processing recipe for performing the work of the "input process B" to the equipment CPU unit 51a of the equipment module 50 with module number 253. The integrated CPU unit 31a also transmits information on a processing recipe for performing the work of the "coating process C" to the equipment CPU unit 51a of the equipment module 50 with module number 10. The integrated CPU unit 31a also transmits information on a processing recipe for performing the work of the "image inspection process B" to the equipment CPU unit 51a of the equipment module 50 with module number 15. The integrated CPU unit 31a also transmits information on a processing recipe for performing the work of the "recovery process A" to the equipment CPU unit 51a of the equipment module 50 with module number 3.

When the equipment CPU unit 51a receives the processing recipe information from the integrated CPU unit 31a in step S450, the process proceeds to step S460. In step S460, the equipment CPU unit 51a installs the processing recipe received from the integrated CPU unit 31a. Then, in step S470, the equipment CPU unit 51a determines whether the equipment module 50 in which it is installed is in a state in which it can operate normally in order to execute the installed processing recipe. For example, if the equipment module 50 has a transport device that transports the workpiece, the equipment CPU unit 51a determines whether the equipment module 50 is in a state in which it can operate normally by returning the position of the transport device to the origin.

If it is determined that the equipment module 50 is in a state in which it can operate normally, in step S480, the equipment CPU unit 51a turns on a normal flag indicating that the equipment module 50 is in a state in which it can operate normally. On the other hand, if it is not determined that the equipment module 50 is in a state in which it can operate normally, in step S490, the equipment CPU unit 51a turns off a normal flag indicating that the equipment module 50 is in a state in which it can operate normally.

Returning to FIG. 5, in step S290, the integrated CPU unit 31a determines whether each of the five equipment modules 50 is in a normal state. Specifically, the integrated CPU unit 31a determines whether each of the five equipment modules 50 is in a normal state based on whether the normal flag of the equipment CPU unit 51a of each of the five equipment modules 50 is on.

If it is determined that all five equipment modules 50 are in a normal state, in step S295, the integrated CPU unit 31a sends a start-up signal to the equipment CPU unit 51a of each of the five equipment modules 50. This puts the production line in a state where the product with production number "Y" can be produced by the five equipment modules 50. On the other hand, if it is not determined that any one of the five equipment modules 50 is in a normal state, in step S250, the integrated CPU unit 31a outputs an error indicating that the equipment module 50 is in an abnormal state.

As described above, the production instruction system 1 of this embodiment includes a plurality of equipment modules 50 for producing a plurality of types of products, and a BOOTP server 40 that can communicate with each of the plurality of equipment modules 50 via Ethernet. Each of the plurality of equipment modules 50 stores information on a pre-assigned MAC address, and has an equipment CPU unit 51a that transmits information on its own MAC address to the BOOTP server 40.

The BOOTP server 40 stores address information. When the BOOTP server 40 receives MAC address information from a specific equipment CPU unit 51a of a specific equipment module 50 among the multiple equipment modules 50, the BOOTP server 40 sets the IP address of the specific equipment CPU unit 51a based on the address information.

This allows the production instruction system 1 to easily set different IP addresses for the equipment CPU units 51a of the multiple equipment modules 50 without the need for an expert.

Furthermore, the above embodiment provides the following advantages:

(1) In the above embodiment, the product is produced by equipment modules 50 arranged in a predetermined process order in multiple processes. The IP addresses stored in the BOOTP server 40 are determined based on the process order.

This makes it easy to set the IP address of the equipment CPU unit 51a of the equipment module 50 even if the arrangement of the equipment modules 50 is changed depending on the product being produced.

In addition, by determining the IP address based on the process order, it is not necessary to fix the IP address in advance for each equipment CPU unit 51a. In other words, it is not necessary to link the IP address to the MAC address of each equipment CPU unit 51a in advance.

For this reason, even if one of the multiple equipment CPU units 51a fails and the equipment CPU unit 51a needs to be replaced, as shown in Figure 8, the same IP address as the equipment CPU unit 51a before the replacement can be set to the replaced equipment CPU unit 51a. Note that Figure 8 shows an example in which, when one of the four equipment CPU units 51a is replaced, the IP address "192.168.0.2" that was set to the equipment CPU unit 51a before the replacement is set to the replaced equipment CPU unit 51a.

Furthermore, if the number of equipment modules 50 registered in the module registration DB 22 is equal to or greater than the maximum number that can be connected to the same network, and the number of equipment modules 50 that make up one production line is equal to or less than the maximum number, IP addresses can be easily set.

(2) In the above embodiment, an integrated control unit 30 is provided that determines whether multiple equipment modules 50 are arranged in process order.

This makes it possible to detect whether the equipment modules 50 are correctly positioned in the process order.

(3) In the above embodiment, the multiple equipment modules 50 are arranged adjacent to each other in process order. Each of the multiple equipment modules 50 has a QR code reader 53 that detects a MAC address that is pre-assigned to an equipment module 50 that is positioned adjacent to itself among the multiple equipment modules 50. The QR code reader 53 transmits information about the detected MAC address to the integrated control unit 30. The integrated control unit 30 determines whether the multiple equipment modules 50 are arranged in process order based on the MAC address information and address information transmitted from the QR code reader 53 of each of the multiple equipment modules 50.

By doing this, each of the multiple equipment modules 50 can easily detect whether they are arranged in process order by detecting the MAC address information of the equipment CPU unit 51a of the equipment module 50 arranged next to it.

Other Embodiments
Representative embodiments of the present disclosure have been described above, but the present disclosure is not limited to the above-described embodiments and can be modified in various ways, for example, as described below.

In the above embodiment, an example has been described in which the IP addresses stored in the BOOTP server 40 are determined based on the process order, but this is not limiting. For example, the IP addresses stored in the BOOTP server 40 may be determined in advance in association with the MAC addresses of the respective equipment CPU units 51a.

In the above embodiment, an example has been described in which an integrated control unit 30 is provided to determine whether or not multiple equipment modules 50 are arranged in process order, but this is not limiting. For example, the production instruction system 1 may be configured not to include an integrated control unit 30 that determines whether or not multiple equipment modules 50 are arranged in process order.

In the above embodiment, the multiple equipment modules 50 are arranged next to each other in process order. The multiple equipment modules 50 detect the MAC address of the equipment module 50 positioned next to them among the multiple equipment modules 50 using the QR code reader 53. An example has been described in which the integrated control unit 30 determines whether the multiple equipment modules 50 are arranged in process order based on the MAC address information and address information transmitted from the QR code reader 53 of each of the multiple equipment modules 50. However, the present invention is not limited to this.

For example, the MAC address of the equipment module 50 may be detected using a method other than the QR code reader 53, such as a camera.

In the above-described embodiment, it goes without saying that the elements constituting the embodiment are not necessarily essential, except in cases where it is specifically stated that they are essential or where they are clearly considered essential in principle.

In the above-described embodiments, when numerical values such as the number, values, amounts, ranges, etc. of components of the embodiment are mentioned, they are not limited to the specific numbers, except when it is expressly stated that they are essential or when they are clearly limited to a specific number in principle.

In the above-described embodiments, when referring to the shapes, positional relationships, etc. of components, etc., there is no limitation to those shapes, positional relationships, etc., unless specifically stated otherwise or in principle limited to a specific shape, positional relationship, etc.

The facility management server 10, production management server 20, integrated PLC unit 31, BOOTP server 40, facility PLC unit 51, and each of the methods disclosed herein may be realized by a dedicated computer provided by configuring a processor and memory programmed to execute one or more functions embodied in a computer program. The facility management server 10, production management server 20, integrated PLC unit 31, BOOTP server 40, facility PLC unit 51, and each of the methods disclosed herein may be realized by a dedicated computer provided by configuring a processor with one or more dedicated hardware logic circuits. The facility management server 10, production management server 20, integrated PLC unit 31, BOOTP server 40, facility PLC unit 51, and each of the methods disclosed herein may be realized by one or more dedicated computers configured by a combination of a processor and memory programmed to execute one or more functions and a processor configured with one or more hardware logic circuits. In addition, the computer program may be stored in a computer-readable non-transient tangible recording medium as instructions executed by a computer.

40 Server device 50 Production equipment 51a Equipment control unit

Claims (4)

A production instruction system for producing a plurality of types of products,
A plurality of production facilities (50) for producing the plurality of types of products;
a server device (40) capable of communicating with each of the plurality of production facilities via Ethernet;
The plurality of production facilities each have an equipment control unit (51 a) that stores information on a MAC address that is assigned in advance and transmits information on the MAC address of the production facility to the server device,
The server device stores address information linking the multiple production equipment corresponding to each of the multiple types of products, information on the MAC address pre-assigned to each of the equipment control units, and information on an IP address that can be set in the equipment control unit, and when it receives MAC address information from a specific equipment control unit of a specific production equipment among the multiple production equipment, the production instruction system sets the IP address of the specific equipment control unit based on the address information. The plurality of types of products are produced in a plurality of processes by the production equipment that are arranged in a predetermined process order,
2. The production instruction system according to claim 1, wherein the IP address stored in the server device is determined based on the process sequence. The production instruction system according to claim 2, further comprising an arrangement determination unit (31a) that determines whether the plurality of pieces of production equipment are arranged in the process order. The plurality of production facilities are arranged adjacent to each other in the process order, and an address detection unit (53) is provided for detecting a MAC address previously assigned to a production facility located adjacent to the plurality of production facilities,
The address detection unit transmits information of the detected MAC address to the placement determination unit,
The production instruction system according to claim 3, wherein the placement determination unit determines whether the plurality of production facilities are placed in the process order based on MAC address information and the address information transmitted from the address detection unit for each of the plurality of production facilities.

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