Production control method and system therefor

• US 5,321,619 A
• Filed: 02/11/1992
• Issued: 06/14/1994
• Est. Priority Date: 09/17/1990
• Status: Expired due to Term

• Current Assignee: Honda Giken Kogyo Kabushiki Kaisha (Honda Motor Company)
• Original Assignee: Honda Giken Kogyo Kabushiki Kaisha (Honda Motor Company)
• Inventors: Otabe, Makoto, Matsuda, Kinji
• Primary Examiner(s): RUGGIERO, JOSEPH F
• Application Number:
  US07/829,071
• Time in Patent Office: 854 Days
• Field of Search: 364/468, 364/478, 364/401-403, 364/131-135, 235/375, 235/376, 235/385, 235/383
• US Class Current: 700/116
• CPC Class Codes: B62D 65/005 Inspection and final control devices
• CPC Class Codes: G05B 19/41865 characterised by job scheduling, process planning, material flow
• CPC Class Codes: G05B 2219/31086 Communication of carriage, agv data, workpiece data at each station
• CPC Class Codes: G05B 2219/31283 Communication memory, storage, ram, eprom on workpiece or pallet
• CPC Class Codes: G05B 2219/31296 Identification, pallet object data and program code for station
• CPC Class Codes: G05B 2219/31297 Read only that ide information which is needed for specific operation
• CPC Class Codes: G05B 2219/31298 Store on actual pallets also id of several other upstream, following pallets
• CPC Class Codes: G05B 2219/31299 If workpiece rejected, write in id and erase operation code
• CPC Class Codes: G05B 2219/31301 Restore lost id by using entry number of preceding, following pallet
• CPC Class Codes: G05B 2219/31302 Verify id data and reread, rewrite or alarm on fault
• CPC Class Codes: G05B 2219/31303 If workpiece transferred to other pallet, transfer also id
• CPC Class Codes: G05B 2219/31432 Keep track of conveyed workpiece, batch, tool, conditions of stations, cells
• CPC Class Codes: G05B 2219/32066 Central stores operation code in id and in concerned station
• CPC Class Codes: G05B 2219/32067 Change combinations of operation codes in station, id for flexibility
• CPC Class Codes: G05B 2219/32068 Execution at station only permitted if operation code of station and id equal
• CPC Class Codes: G05B 2219/32069 Use of multiple id to prepare program for station before pallet in station
• CPC Class Codes: G05B 2219/32121 Read identification of pallet, conveyor and enter data for manufacturing
• CPC Class Codes: G05B 2219/33192 Radio link, wireless
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A method and a system of production control for a production line composed of a plurality of automatic machines, in which input of control data and change of contents of the data required for control of the automatic machine can easily and efficiently be made. Identification data fed from the host computer (30) are converted by a data converter (31) into control data for automatic machines (11) in each process and stored in a storage medium (20) so that each automatic machine may be controlled after the storage medium has been moved together with the workpiece, by control data read out from the storage medium in each process in the production line. The storage medium store not only control data for the workpiece moving together with this storage medium but also those for a plurality of work pieces positioned on the upstream side of the workpiece in the production line and, thereby, prepares the relative automatic machines to be ready for the subsequent stage of operation.

Claims

1. A production control system comprising:

a host computer for outputting identification data for identifying products;

a plurality of automated processing units (APUs) disposed at predetermined locations in a production line, said APUs for conducting processing in accordance with operation instruction data;

data converting means having text files which store the relationship between said operation instruction data and said identification data, said data converting means for generating said operation instruction data from said identification data by referring to said text files;

information storage means being respectively disposed on and moving together with a plurality of objects to be processed (OBJs) flowing along said production line, said information storage means for storing the contents of processing to be applied to said OBJs;

data writing means for writing said operation instruction data generated by said data converting means in information storage means of OBJs corresponding to said operation instruction data;

first reading means for reading information from an information storage means of one OBJ existing at a predetermined location on said production line; and

control means for controlling said APUs in accordance with said information read from said information storage means by said reading means so that said APUs process said one OBJ with predetermined processing;

said information storage means comprising a plurality of storage regions for respectively storing information about one said OBJ and information about other OBJs located in a predetermined range upstream of said OBJ along said production line.

2. The production control system according to claim 1, wherein said data converting means having files for compression conversion of data, said data converting means for compression-converting said operation instruction data by referring to said files for compression conversion of data, said data writing means for writing said compression converted operation instruction data in information storage means of OBJs corresponding to said compression converted operation instruction data, each of said APUs for reading said compression converted operation instruction data from said information storage medium of said corresponding object to be processed, each of said APUs for conducting processing in accordance with said read compression-converted operation instruction data.

3. The production control system according to claim 1 or 2, wherein said control means permits processing to be performed on one of said OBJs by said APU only when said contents of processing to be applied currently on said one of OBJs coincide with said contents of processing on another one said OBJs which had been previously processed.

4. The production control system according to claim 1 or 2, further comprising:

erasing means for clearing contents of an information storage means attached to said transporting means separated from an OBJ at the exit of said production line and transported to the entrance of said production line, and

write-permit determination means for determining whether said contents of said information storage means is cleared, before said data writing means conducts writing, whereby said write-permit determinating means enables said writing means if said contents of said information storage medium is cleared, and disables said writing means if said contents of said information storage medium is not cleared.

5. The production control system according to claim 4, wherein said data writing means comprising:

second reading means for reading said written information from said information storage medium,

coincidence determination means for determining whether the result read by said second reading means coincides with said information to be written by said data writing means, and

alarm means which rewrites said information to be written when said coincidence is determined to not exist, and activates an alarm in the case where said coincidence is not detected after said rewriting is conducted a predetermined number of times.

6. The production control system according to claim 1 or 2, wherein said APUs, in addition to processing said one OBJ in accordance with information on said one OBJ, stored in said one information storage medium, conduct preparation work necessary for processing said other OBJs located in a predetermined range upstream from one said OBJ, along said production line, in accordance with information on said other OBJs.

13. The production control system according to claim 1 or 2, further comprising:

transfer means for transferring objects to be processed form an introduction part of a plurality of production lines and to transfer each production line to a delivery part and then to circulate the production line after moving to said introduction part again after delivering said objects to be processed;

storage means for storing information regarding said objects to be processed;

reading means for reading said information from the storage means provided at said transferring means when said transferring means, provided with objects to be processed, reaches a delivery part of a production line;

storage means for storing said information read by said reading means;

writing means for writing said information to be stored by said storage means into a storage medium which is provided at said transferring means existing in another production line; and

writing means for writing information to be stored by said storage means into a storage medium which is provided at said transferring means when said objects to be processed reach a transferring means existing at an introduction part of another production line.

14. The production control system according to claim 1 or 2, further comprising;

transfer means for transferring objects to be processed from an introduction part of a plurality of production lines and to transfer each said production line to a delivery part, and then to circulate the production line after moving to said introduction part again after delivering said objects to be processed;

intermediate transferring means to transfer said objects to be processed from the delivery part of one production line to the introduction part of another production line;

a storage medium for storing information regarding said objects to be processed which is provided at said transferring means;

reading means to read said information from the storage medium which is provided at said transferring means when said transferring means which is provided with objects to be processed reaches a delivery part of one production line;

first storage means to store said information read by said reading means;

second storage means for reading information within the first storage means when said objects to be processed are placed at said intermediate transferring means;

third storage means for reading information within said second storage means when said objects to be processed are carried to an introduction line of another production line; and

writing means for writing information within said third storage means into said transferring means when said objects to be processed are placed at a transferring means existing at an introduction part of another production line.

15. The production control system according to claim 14, wherein said intermediate transferring means comprises a plurality of continuous transferring means, said second storage means comprises a plurality of storage areas corresponding to each transferring part, each storage area reading information form a storage area of a previous stage when objects to be processed are placed at a corresponding transferring part, and said third storage means reading information form a storage area at a final stage of said second storage means when objects to be processed are carried to an introduction part of another production line.

16. The production control system according to claim 1 or 2, comprising:

transferring means for transferring objects to be processed from an introduction part of a plurality of production lines and to transfer each production line to a delivery part, and then to circulate the production line after moving to said introduction part again after delivering said objects to be processed;

intermediate transferring means for transferring said objects to be processed form a deliver part of one production line to an introduction part of another production line;

a storage medium to store information regarding said object to be processed which is provided at said transferring means and said intermediate transferring means;

reading means for reading said information form a storage medium which is provided at said transferring means when said transferring means which is provided with objects to be processed reaches a delivery part of one production line;

first storage means for storing said information read by said reading means;

writing means for writing information which said second storage means stores into a storage medium which is provided when said objects to be processed reach a transferring means existing at an introduction part of another production line; and

writing means for writing information to be stored into said second storage means into a storage medium which is provided at said transferring means when said objects to be processed reach a transferring means existing in an introduction part of another production line.

17. The production control system according to claim 1 or 2, wherein each automated processing unit is provided with a storage medium used to store processing information regarding objects to be processed and with reading means for reading information from this storage medium and then outputting the information to an upper-level controller, the production control system further comprising;

transferring means for transferring objects to be processed which are fed from an introduction part of a production line in sequence;

storage means which is provided at said transferring means; and

processed information reading means for reading said storage medium, wherein processing information regarding objects to be processed is fed from an upper-level controller previously being based on production control information, wherein a plurality of automated processing units which are disposed along the travelling direction of objects to be processed are operated in sequence, being based on operation information from said upper-level controller corresponding to processing information stored at said storage medium for performing a predetermined processing to said objects to be processed.

18. The production control system according to claim 1 or 2, comprising a plurality of input means such as a bar code reader or a keyboard for entering processing information regarding objects to be processed into a network and conversion means for performing conversion-processing to enable input information to be of the same format as information of the above processing details of said upper-level controller, wherein said production line is provided with transferring means for transferring objects to be processed which are fed form an introducing part of a production line in sequence, storage means which is provided at this transferring means, an upper-level controller which sets and stores processing details regarding objects to be processed on the production line, and processing information reading means for reading said storage medium where processing information regarding the objects to be processed, which is sent from the upper-level controller previously being based on production control information, and which enables a predetermined processing to be made to said objects to be processed by operating a plurality of automated processing units which are placed along the travelling direction of objects to be processed in sequence, being based on operation information from said upper-level controller corresponding to processing information which is stored in said storage medium.

19. The production control system according to claim 1 or 2, further comprising:

transferring means for transferring objected to be processed form an introduction part of a production line to a deliver part and for moving to said introduction part again after the objects to be processed are delivered, and for circulating the production line;

automated processing units which are provided along said production line and process objects to be processed which are carried by the transferring means in sequence;

storage means which is provided at said transferring means and for storing receiving product identification information writes information into said storage medium, or reads and outputs information from said storage medium;

a lower-level controller which selects an operation pattern corresponding to the output of said reading/writing means out of a previously stored plurality of operation patterns corresponding to output from said reading/writing means, controls said automated processing units, and outputs data of the objects to be processed, being processed by said automated processing units; and

an upper-level controller which outputs product identification information to said storage medium through said reading/writing means and receives data of said objects to be processed through a network.

20. The production control system according to claim 1 or 2, wherein predetermined processing is performed in sequence on objects to be processed by enabling controlling means, which is provided at each process, to control a plurality of processes which are disposed along the travelling direction of objects to be processed, and said controlling means at each process supplies information which is supplied from a sensor which detects the condition of processing to be executed at said process to upper-level control means for controlling each controlling means.

21. The production control system according to claim 1 or 2, wherein a predetermined processing is performed for said objects to be processed in sequence by enabling controlling means at each process to control a plurality of processes which are disposed along the traveling direction of said objects to be processed, being based on data written into a storage medium which moves in one piece with said objects to be processed comprising;

a sensor for detection processing conditions to be executed during said process; and

writing means for writing information detected by said sensor into said storage medium.

22. The production control system according to claim 20, further comprising repair means for performing repairs necessary on objects to be processed, the repairs being based on information which is supplied from said upper-level control means provided downstream of said plurality of processes.

23. The production control system according to claim 21, further comprising repair means for repairing objects to be processed, the repairs being based on information written into said storage medium downstream of said plurality of processes.

24. The production control system according to claim 22, wherein said repair means comprises an image data storage part for storing image data corresponding to said repair information and a display part for displaying image data read from said image data storage part.

25. The production control system according to claim 23, wherein said repair means comprises reading means for reading information from said storage medium, repair discriminating means for outputting repair information regarding the details of the repair processing needed according to information supplied from said reading means, an image data storage part for storing image data corresponding to said repair information, and a display part for displaying image data read from said image data storage part.

7. A control method for production line comprising the steps of:

storing in each of information storage means moving together with a plurality of objects to be processed moving along said production line, respective information about the contents of processing which are to be applied by automated processing units (APUs) to one OBJ, and about the contents of processing which are to be applied by said APUs to others OBJs located at up to an ith location in succession on the upstream side of said one OBJ along said production line;

reading information from an information storage means moving together with one said OBJ;

causing said APUs to apply to said one OBJ on said information corresponding to said one OBJ only when a coincidence exists between information about said one OBJ, read from said one information storage means corresponding to said one OBJ, and information about said one OBJ, read from an information storage means of another OBJ processed by said APUs prior to said reading from said corresponding information storage unit;

said control method for a production line further comprising the step of;

replacing information, in the case where an OBJ is removed from said production line, at a location up to an ith location on the upstream side of said one OBJ to be processed, said step of replacing information including replacing information, stored in a group of information storage means, about OBJs on the upstream side of said removed OBJ, with information about OBJs upstream respectively adjacent to said OBJs on the upstream side of said removed OBJ stored, said group of information storage means being disposed on OBJs located at up to an ith location in succession on the downstream side of said removed OBJ.

12. The control method for a production line according to any one of claims 7 to 9, wherein said information replacing is performed by information supply means.

8. A control method for a production line comprising the steps of:

storing in each of information storage means moving together with a plurality of transporting means, on which a plurality of objects to be processed (OBJs) are respectively disposed, moving along said production line, respective information about the contents of processing which are to be applied by automated processing units (APUs) to one OBJ, and about the contents of processing which are to be applied by said APUs to other OBJs, disposed on said transporting means, located at up to an ith location in succession on the upstream side of said one OBJ along said production line;

reading information from an information storage means moving together with one said OBJ;

causing said APUs to apply to said one OBJ on said information corresponding to said one OBJ only when a coincidence exists between information about said one OBJ, read from said one information storage means corresponding to said one OBJ, an information about said one OBJ, read from an information storage means of another OBJ processed by said APUs prior to said reading from said corresponding information storage means;

said control method for a production line further comprising the step of;

writing information, in the case where an OBJ is removed from one transporting means on said production line, said step of writing information including writing information that no OBJ exists, in storage regions of an information storage medium disposed on said one transporting means and in storage regions of information storage means disposed on a group of transporting means located at up to an ith location in succession on the downstream side of said one transporting means, said storage regions corresponding to said removed OBJ and OBJs disposed on said group of transporting means, and for replacing said information that no OBJ exists, stored in said storage regions, with information about said new OBJ when a new OBJ is mounted on said one transporting means, from which said one OBJ was removed.

9. A control method for production line comprising the steps of:

storing in each of information storage means moving together with a plurality of objects to be processed (OBJs) moving along said production line, respective information about the contents of processing which are to be applied by automated processing units (APUs) to one OBJ, and about the contents of processing which are to be applied by said APUs to others OBJs located at up to an ith location in succession on the upstream side of said one OBJ along said production line;

reading information storage means moving together with one said OBJ;

causing said APUs to apply to said one OBJ on said information corresponding to said one OBJ only when a coincidence exists between information about said one OBJ, read from said one information storage means corresponding to said one OBJ, and information about said one OBJ, read from an information storage means of another OBJ processed by said APUs prior to said reading from said corresponding information storage means;

said control method for a production line further comprising the steps of;

placing anew OBJ on the downstream side of an OBJ located at a not-less-than-the-ith location on the upstream side of said one OBJ being processed by said APUs;

storing in an information storage means of said new OBJ, information about said new OBJ and information about a group of OBJs located at up to an ith location in succession on the upstream side of said new OBJ, along said production line; and

writing information about said new OBJ, in storage regions of information storage means of OBJs located at up to an ith location in succession on the downstream side of said new OBJ, said storage regions corresponding to said new OBJ, and for replacing information, stored in storage regions corresponding to OBJs on the upstream side of said new OBJ, with information about OBJs downstream adjacent to said OBJs on the upstream side of said new OBJ.

10. A production control system comprising:

information storage mediums being respectively disposed on and moving together with a plurality of objects to be processed (OBJs), said information storage mediums for storing the contents of processing to be applied to said OBJs;

first reading means for reading information from one of said information storage medium disposed on one of said OBJs existing at a predetermined location on said production line;

data writing means for writing information in said one information storage medium;

a control unit for controlling automated processing units (APUs) in accordance with said information read from said one information storage medium by said reading means so that said APUs apply predetermined processing to said one OBJ; and

discriminating means for discriminating whether an OBJ has been removed from said production line;

said information storage mediums comprising a plurality of storage regions for respectively storing information about said one OBJ, and information on OBJs located between a predetermined range of distance on the upstream side of said one OBJ, along said production line;

said discriminating means for discriminating whether an OBJ has been removed from said production line, and whether a new OBJ has been placed in said production line, at a not-less-than-the-ith location on the upstream side of said one OBJ;

said data writing means for replacing information, stored in a group of information storage mediums, about OBJs on the upstream side of said removed OBJ, with information about OBJs upstream respectively adjacent to said OBJs on the upstream side of said removed OBJ stored, said group of information storage mediums being disposed on OBJs located at up to an ith location in succession on the downstream side of said removed OBJ when said removal of said OBJ is discriminated by said discriminating means;

said data writing means for writing information about said new OBJ, in storage regions of information storage mediums disposed on OBJs located at up to an ith location in succession on the downstream side of said new OBJ, said storage regions corresponding to said new OBJ, and for replacing information, stored in storage regions corresponding to OBJs on the upstream side of said new OBJ, with information about OBJs downstream adjacent to said OBJs on the upstream side of said new OBJ, when said placement of said new OBJ is discriminated by said determining means;

said control unit for controlling said APUs, in accordance with information on said one OBJ read out currently from said one information storage medium only when said information on said one OBJ read out currently from said one information storage medium and information on said one OBJ read out last time from said one information storage medium.

11. A production control system comprising:

information storage mediums being respectively disposed on and moving together with a plurality of objects to be processed (OBJs), said information storage mediums for storing the contents of processing to be applied to said OBJs;

first reading means for reading information from one of said information storage medium disposed on one of said OBJs existing at a predetermined location on said production line;

data writing means for writing information in said one information storage medium;

a control unit for controlling automated processing units (APUs) in accordance with said information read from said one information storage medium by said reading means so that said APUs apply predetermined processing to said one OBJ; and

discriminating means for discriminating whether an OBJ has been removed from said production line;

said information storage mediums comprising a plurality of storage regions for respectively storing information about said one OBJ, and information on OBJs located between a predetermined rage of distance on the upstream side of said one OBJ, along said production line;

said discriminating means for discriminating whether an OBJ has been removed from said production line, and whether a new OBJ has been placed in said production line, at a not-less-than-the-ith location on the upstream side of said one OBJ;

said data writing means for writing information that no OBJ exists, in storage regions of an information storage medium of said removed OBJ and in storage regions of information storage mediums disposed on OBJs locate at up to an ith location in succession on the downstream side of said removed OBJ, said storage regions corresponding to said removed OBJ, when said removal of said removed OBJ is discriminated by said discriminating means, and for replacing said information that no OBJ exists, stored in said storage regions, with information about said new OBJ when the placement of a new OBJ on said one transporting means from which said one OBJ was removed, is discriminated by said discriminating means;

said control unit for controlling said APUs, in accordance with information on said one OBJ read out currently from said one information storage medium only when said information on said one OBJ read currently from said one information storage medium and information on said one OBJ read last time from said one information storage medium.