JPS619703A - Factory automation system - Google Patents

Abstract

PURPOSE:To minimize the effect of the breakdown of either one of a central control system and a circulation control system, by having the production schedules of the same contents and various data between both systems at a time. CONSTITUTION:The overall control is given to both a central control system 102 and a circulation control system 107 according to a production shedule. The schedule operation is usually carried out in a primary mode under the control of the system 102. If a computer 102a of the system 102 has a fault, a follower mode is indicated automatically or via a console. Thus the operation is controlled hereafter according to the production schedule and under the control of a circulation computer 107a of the system 107. In other words, the system 107 substitutes the function of the computer 102a of the system 102 to control an electronic file 102c, a printer 102f and a color display devide 102e in addition to its original circulation control. Furthermore the system 107 transfers the control commands and data among processing cells 104a-106a.

Description

[Detailed Description of the Invention] <Industrial Application Field> The present invention relates to an IT factory automation system, in particular a plurality of processing cells, a central management system that controls each processing cell according to a production schedule, and a production system. It has a logistics control system that controls the logistics of workpieces and other items according to schedules, and a local area network (LAN) that connects each processing cell, central management system, and logistics control system so that they can communicate with each other. A factory automation system that mutually exchanges data between systems with two different purposes, called logistics control systems, so that they have the same data on predetermined items, so that even if one system goes down, only the other system can operate. About the system.

<Prior Art> In the context of rising material prices and labor costs and a shift from mass production to high-mix, low-volume production, a production system that provides higher efficiency is required.

For this purpose, a large number of processing cells including numerical control machine tools and robots are installed, as well as a logistics system including automated warehouses and automatic guided vehicles, and a central management system controls the operation of these processing cells and logistics systems according to the production schedule. schedule operation, logistics control), the operating status of each processing cell and automated guided vehicle, and the production progress status of each processing cell.
FA that outputs to the 710 device, manages NC programs (storage, modification, deletion, transfer, etc.), and performs other management.
The system is in the spotlight.

<Problem that the invention is trying to solve> Now, the conventional F
In system A, a production schedule is input into a central management system, and the central management system then controls the operation of a large number of processing cells and distribution control systems in accordance with the production schedule.

However, in such conventional FA systems, if the central management system or logistics control system goes down for some reason, the machining performance data up to that point will be lost, and operations will no longer be able to follow the production schedule. We have no choice but to stop production.

Therefore, the purpose of the present invention is to ensure that even if either the central management system or the logistics control system goes down, the data up to that point will not be lost, and that operations can continue according to the production schedule while minimizing the impact of the downtime. and Party B, which provides an FA system that can.

<Means for Solving the Problems> FIG. 1 is a schematic configuration diagram of the FA system according to the present invention.
... has a processing cell, each of which has at least an NC device with a built-in processor, a machine tool controlled by the NC device, a robot control device with a built-in processor, and a robot controlled by the four-bot control device. ing.

107 is a logistics control system, automated warehouse,
Equipped with an automatic guided vehicle and a logistics control computer, it transports workpieces to predetermined processing cells or imports processed parts as appropriate according to the production schedule. 102, each processing cell 104a..., 1 according to the production schedule
05a..., 106a... Central management system that performs operation control, cannibal program management, centralized abnormality monitoring, etc., 10
Reference numeral 3 denotes a local area network (LAN) that connects each of the processing cells, the central WEI system, and the logistics control system in a communicable manner. The NC device, robot control device, and processor-equipped unit constituting the central management system 102 of each processing cell 104a..., 105a..., 106a... are connected to the local area network (
LAN) 103, and is configured so that control commands and data can be transferred between each unit according to a predetermined protocol.

<Function> Central management system 102 and logistics control system 1
Both systems are capable of scheduled operation by controlling the other system according to the production schedule.

Of both systems, the system into which the production schedule has been input transfers the production schedule to the other system and gives instructions according to the production schedule, and the other system stores the production schedule and Processing is carried out in accordance with the instructions from the system, and thereafter the systems on the side constantly exchange data with each other to have the same data for predetermined items, while synchronizing the control of the processing cell and the control of logistics. Execute scheduled operation. If a failure occurs in one of the logistics control system and the central management system, the system in which the failure has occurred is separated and operation is performed using only the other system.

<Embodiment> FIG. 2 is an overall block diagram of the FA system according to the present invention, in which 102 is a central management system, 103 is a LAN,
104, 105, and 106 are processing cell groups each consisting of a plurality of processing cells, and 107 is a distribution control system.

The central management system 102 includes a computer 102a1, a program file 102c configured by a large capacity memory (for example, a magnetic disk) for storing a large number of Canadian programs and robot control data, and a processor, which automatically creates Canadian programs and robot control data; Automatic programming device 'l O2d that stores the created program in the program file 102C, as appropriate (a
) Operation status of processing cells, automated warehouses, and automated guided vehicles, (b)
A color display device 102e that displays the daily or monthly production progress for each processing cell; a printer 102f that is connected to the computer 102a and also prints out the operating status, production progress, schedule list for each processing cell, etc. , has a LAN unit 102g configured as a programmable controller (PC) that constitutes a part of the LAN 103.

In the main mode, the computer 102a receives production schedules and other data from a host device or data input device (not shown), and also controls processing cells and logistics control systems 10 according to the production schedules.
7, further controls the printer 102f,
The schedule list for each processing cell, operation list, production progress list, etc. are printed, and the operation results, production results, and other data of each processing cell are displayed on a color display device using data sent from the logistics control system 107. 102e, and performs various other controls such as program management. It should be noted that the computer 102a notifies the logistics control system 107 of the fact and the details of the data every time a predetermined event occurs or whenever stored data is modified or added, and also notifies the logistics control system 107 of the data details sent from the logistics control system. In addition to storing data that is sent from the distribution control system, it also executes schedule operation control while referring to events sent from the logistics control system.

That is, the central management system and the logistics control system constantly exchange data with each other, have the same data regarding predetermined items, and perform scheduled operations while synchronizing control of processing cells and control of logistics.

On the other hand, in the slave mode in which schedule operation control is performed under the control of the logistics control system, the computer 102a receives the production schedule from the logistics control system and stores it in its built-in memory, and also sends each processing based on instructions from the logistics control system 107. Control cells or manage programs.

The program file 102C connects the automatic programming device 102d and the computer 102a to exchange data at high speed. (a) Register (storage) the Canadian program and robot control data created by the automatic programming device 102d in the built-in memory;
b) Modify an already created Canadian program,
(C) In response to a command from the computer 102a, the machine program and robot control data stored in the built-in memory are transferred to the processing cell according to a predetermined protocol and stored in the memory, and (d) requested from the operation panel of the processing cell. The processed cannibal program is similarly transferred to the processing cell.

The LAN unit 102g that constitutes a part of the LAN includes
Computer 102a, logistics control system 1
07, each program file 102C has one R
8232C transmission line (metal cable) MLI, ML2,
Connected via ML3. Note that an optical fiber may be used as the transmission path. Also, LAN10
2g includes a plurality of lower-level LAN units 103a, which will be described later.
.

103b and 103c are connected via one optical fiber OFI and OF2.6F3, respectively.

LAN unit 103a that constitutes LAN 103,
103b and 103c are provided for each processing cell group 104, 105, and 106 each consisting of a plurality of processing cells, and each LAN unit 103a
~103C is one optical fiber 0Fi (i
=1.2.3) to the LAN unit 102g of the central management system. Also, processing cell group 104.1
The NC device and robot control device of each processing cell that make up the 05.106 are connected to a corresponding LAN unit via one R3232C transmission line or optical fiber) 1
Connected to 03a, 103b, 103c.

The processing cell group 104 includes three processing cells 104a.

104b, 104c, and the processing cell group 105 has two processing cells 105a, 105. b, addition, le group 1
06 has two processing cells 106a and 106b, each processing cell has an NC device (CNC) with a built-in processor, and
It has a machine tool MT controlled by a C device, a robot control device RBC with a built-in processor, and a Rero Hot RB controlled by the robot control device.

The logistics control system 107 includes a logistics control computer 107a, an automated warehouse 107b, and an automatic guided vehicle 1.07c. And in the main mode, the central control system 10 according to the production schedule
Based on the instructions inputted from 2, the workpiece is transported from the automated warehouse to a predetermined processing cell, and the processed parts are transported from the processing cell to the automated warehouse. Furthermore, the central management system 10
2 events (start/end of data transfer to each processing cell, instruction to start processing to the processing cell, completion of processing from the processing cell, etc.)
If information and data (data indicating the operating status of each processing cell, Canadian program management data, production schedule list, etc.) are input, these will be stored or processed according to the event, and the logistics control system will record the event (e.g. When a workpiece transfer instruction, workpiece transfer completion) occurs, these are notified to the central management system, and the data stored in the logistics control system side (operating status of each processing cell, automated warehouse, automatic guided vehicle, production progress status, etc.) is sent to the central management system 102.

On the other hand, the production schedule is logistics control system 1
07, and in the slave mode in which the logistics control system controls scheduled operation according to the production schedule, the system instructs, for example, the central management system to send a predetermined program and robot control data to a predetermined processing cell according to the production schedule. It also instructs the transport vehicle to transport the work to a predetermined processing cell, or to transport parts from the processing cell to an automated warehouse. In addition, each time the logistics control system and the central management system modify or add stored data, they notify the other system of the details, and each time a predetermined event occurs, they notify the other system to that effect. The conditions are equal.

Next, the operation in the main mode will be explained with reference to the time chart of FIG.

Now, when a production schedule is input to the central management system 102 from a host device or data input device (not shown) in the main mode, the central management system 102 first compares the stored data with the logistics control system and stores each other's stored contents before starting up. Match. As a result, the logistics control system also stores the production schedule.

Next, the central management system reads the operating status of each processing cell (scheduled operation, individual operation, pause, failure, stop) from each processing cell, updates the processing cell operating status data, and notifies this to the logistics control system 107. do.

Then, the central management system 102 transmits control commands and data to each processing cell and logistics control system in a predetermined transmission format, taking into account the production schedule and the operating status of the processing cell. That is, the distribution control system 107 is instructed to transport 10 tons of workpieces to a predetermined processing cell, and the program file 102C is sent to a predetermined NC device, a machine program and robot control data to a robot control device. instruct.

As a result, the logistics computer 107a
7b and the automatic guided vehicle 107c to transport the workpiece, and the program file 102C transmits a predetermined program and robot control data to the LAN units 102g, 103a to 103a according to a predetermined protocol.
It is transferred to the NC device CNC and robot control device RBC of each processing cell via 103c.

Once the workpiece has been transported, the logistics control system 1
The physical distribution control computer 107a of No. 07 reports the completion of transportation to the central management system 102. In addition, when each processing cell finishes receiving the Cannibal program and robot control data, the central management system 10 indicates the completion of receiving the Cannibal program via the LAN units 103a to 103c and 102g.
The central management system 102 notifies the physical distribution control system 107 of this fact.

When the preparation for processing is completed as described above, the computer 102a
commands each machining cell to start operation, and machining is performed by the machining cell. Note that the physical distribution control system 107 is notified that processing has been instructed to the processing cell.

After that, processing is performed by the processing cell, and in parallel with the processing, the central management system 102 operates the logistics control system 1.
The logistics control system 107 outputs logistics control data corresponding to the next loft to the next loft, and the logistics control system 107 controls the automatic guided vehicle and the automated warehouse in the same manner as described above based on the logistics data.

When each machining cell completes machining for 10 tons, it notifies the computer 102a that machining is complete. As a result, the computer 102a of the central management system 102 notifies the logistics control system 107 of the completion of processing, and also transmits the four grams of cane nib used for processing the next lot and the robot control data to the processing cell that outputs the processing completion signal. send to

The distribution control system 107 controls the automatic guided vehicle 107c based on the notification of completion of processing to transport the processed parts from the processing cell to the automated warehouse, and when the delivery is completed, notifies the central management system 102 that the delivery is complete. do.

Thereafter, processes similar to those described above are performed one after another, and finally machining according to the production schedule is automatically performed.

The above is a case of the main mode in which scheduled operation is performed under the control of the central management system 102, but almost the same control is performed in the case of the slave mode in which scheduled operation is performed under the control of the physical distribution control system 107. The main mode and the slave mode differ in that (a) the production schedule is input into the logistics control system 107, and (b)
) The central management system 102 controls the transfer of control commands and data to processing cells based on instructions from the logistics control system 107; other points are the same; the central management system and the logistics control system are the same. Scheduled operation is performed by exchanging data with each other to make their states the same, and by synchronizing processing cell control and logistics control.

As described above, both the central management system and the logistics control system can perform overall control according to the production schedule, but normally schedule operation is performed under the control of the central management system 102 in the main mode. If the computer 102a of the central management system 102 goes down due to a failure, the logistics control system 102 can be activated automatically or by commanding the slave mode from the console.
Operation control according to the production schedule is executed under the control of the physical distribution computer 1Q7a of No.7. That is, in addition to the original physical distribution control, the physical distribution control system 107 performs the functions of the computer 102a of the central management system to control the electronic file 102C1 printer 102f and the color display device 102e, and also performs control between each processing cell. Sends and receives commands and data.

Furthermore, if the central management system 102 goes down completely, it is no longer possible to send the machine program or robot control data to each processing cell. However, the NCC of the processing cell
Since a plurality of cannibal programs and robot control data can be stored in each of the robot control devices RBC in the NCC device CN, a plurality of cannibal programs and robot control data according to the production schedule can be stored in advance in the robot control device RBC in the NCC device CN. I'll let you. If the central management system 102 goes down in this state, the operating state of each processing cell is set to the individual operation mode, and thereafter, processing cell start-up and processing completion signals are input to the physical distribution control system by operator operations. However, transporting the workpiece,
Control of delivery, etc. is performed by the logistics control system 107 according to the production schedule, and the operation results, production results, production progress status, etc. are monitored by the logistics control system. still. The operator controls each processing cell while referring to the schedule list printed out from the printer of the logistics control system.

On the other hand, if the material control system 107 goes down, it is not possible to automatically control physical distribution according to the production schedule. Therefore, from now on, physical distribution such as transportation and loading of the work to the processing cell will be operated by the operator, and each time the transportation or loading is completed, the operator will notify the central management system. The central management system 102 inputs control commands and data (cannibal programs, robot control data, etc.) to each processing cell according to the production schedule, and also monitors operation results, production results, production progress, etc.

<Effects of the Invention> As explained above, according to the present invention, the system into which the production schedule is input between the central management system and the logistics control system transfers the production schedule to the other system, and also transfers the production schedule to the other system. The other system stores the production schedule and processes according to the instructions from the first system, and both systems constantly exchange data with each other to keep their status consistent. Furthermore, since the schedule operation control is performed while synchronizing the control of processing cells and the control of logistics, the central management system and logistics control system always have the same data, thus providing highly reliable FA. system, and even if one system goes down, the impact can be minimized.

In other words, even if one of the systems goes down, there is no risk that operation record data, production record data, etc. will be lost.Furthermore, in the worst case scenario, schedule operation can be performed with the intervention of an operator, thereby reducing the impact of the system going down.

[Brief explanation of the drawing]

Fig. 1 is a block diagram of the FA system according to the present invention, Fig. 2 is a detailed block diagram of the FA system of the present invention, and Fig. 3 is a block diagram of the FA system according to the present invention.
The figure is a time chart explaining the flow of data in the main mode. 102... central management system, 102. a... Computer, 103... LAN1104.105.1
06...Processing cell group 107...Logistics control system, 107a...Logistics control computer 107b...Automated warehouse, 107C...Automated guided vehicle patent applicant FANUC Corporation agent
Patent Attorney Chiki Saito Figure 1

Claims (5)

[Claims] (1) A plurality of machining cells each having at least an NC device and a machine tool each with a built-in processor, and a central management system having a computer and exchanging control commands and data with the machining cells according to a production schedule;
a logistics control system that includes at least a logistics control computer and controls the logistics of workpieces and the like according to a production schedule; and a local area network that connects each of the processing cells, the central management system, and the logistics control system so that they can communicate with each other. Of the central management system and logistics control system, the system into which the production schedule is input forwards the production schedule to the other system and gives instructions according to the production schedule, and the other system inputs the production schedule. A factory automation system characterized in that both systems store data and perform processing according to instructions from one of the systems, and both systems constantly exchange data with each other so that they have the same data for predetermined items. ·system. (2) When a predetermined event occurs in one system, the factory notifies the other system of the event and executes the following process.・Automation system. (3) The event in the central management system includes at least the start of data transfer to each processing cell, the end of data transfer, the instruction to start processing to each processing cell, and the completion of processing from each processing cell, and the event in the logistics control system 2. The factory automation system according to claim 2, wherein the event includes at least an instruction to transfer the workpiece to a transport vehicle and completion of the transfer of the workpiece. (4) The factory system according to claim (1), wherein each of the central management system and the logistics control system notifies the other system of the details each time storage data is changed or added. automation system. (5) If a failure occurs in one of the logistics control system and the central management system, the system in which the failure has occurred is separated and operation is performed only with the other system. ) or (4).