Manufacture condition setting system, manufacture condition setting method, control program, and computer-readable record medium recording control program therein

• US 20060259176A1
• Filed: 04/18/2006
• Published: 11/16/2006
• Est. Priority Date: 04/20/2005
• Status: Active Grant

• Current Assignee: Omron Corporation
• Original Assignee: Omron Corporation
• Inventors: Fujii, Toru
• Granted Patent: US 7,519,446 B2
• Time in Patent Office: Days
• US Class Current: 700/104
• CPC Class Codes: G05B 19/418 Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
• CPC Class Codes: G05B 2219/31324 Distributed real time knowledge, database
• CPC Class Codes: G05B 2219/32187 Correlation between controlling parameters for influence on quality parameters
• CPC Class Codes: G05B 2219/35529 Monitoring current machining, store information in database as a new working case
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A manufacture condition setting system includes a manufacture state acquisition unit to which static/dynamic conditions and a product quality in the case where the static/dynamic conditions do not change for, at least, a predetermined number of manufactured articles in an ordinary manufacture state are inputted together with reference information, a dynamic condition inference unit which estimates and outputs a corresponding optimal dynamic condition in a case where a combination of the static conditions is an experienced one, and a dynamic condition correction unit which, if necessary, corrects inference knowledge stored by the dynamic condition inference unit, by using information inputted from the manufacture state acquisition unit.

Claims

1. A manufacture condition setting system which assists an estimation of a dynamic condition such as a set value of a manufacturing equipment, comprising:

manufacture state acquisition means for acquiring static conditions that include a plurality of items, and a dynamic condition corresponding to the static conditions; and

experience accumulation means for accumulating the static conditions and the dynamic condition in an experience database in association with each other, when the number of manufactured articles manufactured in a state where the static conditions and the dynamic condition are constant is, at least, a predetermined number of manufactured articles.

2. A manufacture condition setting system as defined in claim 1, further comprising:

knowledge building means for registering static conditions and dynamic conditions from the experience database, in a knowledge database in which one dynamic condition is held in association with one static condition;

wherein when a plurality of dynamic conditions of different contents are accumulated in association with static conditions of identical contents, in the experience database, said knowledge building means selects one dynamic condition to be registered in the knowledge database, from the plurality of dynamic conditions, or it generates one dynamic condition to be registered in the knowledge database, on the basis of the plurality of dynamic conditions.

3. A manufacture condition setting system as defined in claim 1, wherein in accumulating the static conditions and the dynamic condition in the experience database in association with each other, said experience accumulation means accumulates the static conditions and the dynamic condition in the experience database by further associating reference information for retrieving them.

4. A manufacture condition setting method in a manufacture condition setting system which assists an estimation of a dynamic condition such as a set value of a manufacturing equipment, comprising the steps of:

allowing manufacture state acquisition means of the manufacture condition setting system to acquire static conditions that include a plurality of items and a dynamic condition corresponding to the static conditions; and

allowing experience accumulation means of the manufacture condition setting system to accumulate the static conditions and the dynamic condition in an experience database in association with each other, when the number of manufactured articles manufactured in a state where the static conditions and the dynamic condition are constant is a predetermined number of manufactured articles.

5. A manufacture condition setting system which assists an estimation of a dynamic condition such as a set value of a manufacturing equipment, comprising:

dynamic condition analogy means operating when any dynamic condition associated with a desired static condition to-be-estimated does not exist in a knowledge database in which one dynamic condition is held in association with one static condition, for selecting one item of a quantitative variable included in static conditions, for extracting static conditions as to which settings of all items with one item further excepted from the other items except one selected item are identical to those of the desired static condition, and for generating a dynamic condition corresponding to the desired static condition, on the basis of dynamic conditions associated with the extracted static conditions.

6. A manufacture condition setting method in a manufacture condition setting system which assists an estimation of a dynamic condition such as a set value of a manufacturing equipment, comprising the step of:

allowing dynamic condition analogy means of the manufacture condition setting system to select one item of a quantitative variable included in static conditions, when any dynamic condition associated with a desired static condition to-be-estimated does not exist in a knowledge database in which one dynamic condition is held in association with one static condition, to extract static conditions as to which settings of all items with one item further excepted from the other items except one selected item are identical to those of the desired static condition, and to generate a dynamic condition corresponding to the desired static condition, on the basis of dynamic conditions associated with the extracted static conditions.

7. A manufacture condition setting system which assists an estimation of a dynamic condition such as a set value of a manufacturing equipment, comprising:

static condition correction means operating when contents of a plurality of dynamic conditions associated with a plurality of static conditions in which settings of only one item differ are substantially identical, in a knowledge database in which one dynamic condition is held in association with one static condition, for unifying the plurality of static conditions and dynamic conditions into one static condition and one dynamic condition, and for deleting the pertinent item from the static conditions.

8. A manufacture condition setting method in a manufacture condition setting system which assists an estimation of a dynamic condition such as a set value of a manufacturing equipment, comprising the step of:

allowing static condition correction means of the manufacture condition setting system to unify a plurality of static conditions and a plurality of dynamic conditions into one static condition and one dynamic condition when contents of the plurality of dynamic conditions associated with the plurality of static conditions in which settings of only one item differ are substantially identical, in a knowledge database in which one dynamic condition is held in association with one static condition, and to delete the pertinent item from the static conditions.

9. A manufacture condition setting system which assists an estimation of a dynamic condition such as a set value of a manufacturing equipment, comprising:

static condition correction means operating when a plurality of dynamic conditions of substantially identical contents exist among a plurality of dynamic conditions associated with a plurality of static conditions in which settings of only one item differ, in a knowledge database in which one dynamic condition is held in association with one static condition, for unifying the plurality of dynamic conditions of substantially identical contents and the plurality of static conditions associated with the dynamic conditions, into one dynamic condition and one static condition, and for unifying the settings of the pertinent item of the plurality of static conditions into one setting.

10. A manufacture condition setting method in a manufacture condition setting system which assists an estimation of a dynamic condition such as a set value of a manufacturing equipment, comprising the step of:

allowing static condition correction means of the manufacture condition setting system to unify a plurality of dynamic conditions of substantially identical contents and a plurality of static conditions associated with the dynamic conditions, into one dynamic condition and one static condition, when the plurality of dynamic conditions of substantially identical contents exist among a plurality of dynamic conditions associated with a plurality of static conditions in which settings of only one item differ, in a knowledge database in which one dynamic condition is held in association with one static condition, and to also unify the settings of the pertinent item of the plurality of static conditions into one setting.

11. A manufacture condition setting system comprising:

condition inference means for reading out conditions and qualities from a database in which conditions including a plurality of items such as set values of a manufacturing equipment are held in association with qualities of manufactured articles manufactured under the conditions in the past, for comparing the read-out conditions, for unifying a plurality of conditions into one and also unifying a plurality of qualities associated with the plurality of conditions, into one, in existence of the plurality of conditions in which settings of alterable items included in the conditions are identical, and for thereafter extracting a condition with which the most excellent quality is associated, from among the conditions after the unifications and the conditions which were not identical in the settings of the alterable items to the other conditions.

12. A manufacture condition setting method in a manufacture condition setting system which assists an estimation of a condition such as a set value of a manufacturing equipment, comprising the step of:

allowing a condition inference means of the manufacture condition setting system to read out conditions and qualities from a database in which conditions including a plurality of items such as set values of a manufacturing equipment are held in association with qualities of manufactured articles manufactured under the conditions in the past, to compare the read-out conditions, to unify a plurality of conditions into one and also unify a plurality of qualities associated with the plurality of conditions, into one, in existence of the plurality of conditions in which settings of alterable items included in the conditions are identical, and to thereafter extract a condition with which the most excellent quality is associated, from among the conditions after the unifications and the conditions which were not identical in the settings of the alterable items to the other conditions.