JP3048873B2 - Production system using self-propelled work center - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a self-propelled work in which a part is transported to each process (work station) by a self-propelled carriage provided with a work table in a production line mainly including an assembly process. And a new production system using the self-propelled work center.

[0002]

2. Description of the Related Art A conventional production line mainly comprising an assembly process arranges a plurality of workstations for assembling, adjusting, and inspecting parts on a floor, and connects these workstations to each other by a belt conveyor. The parts required at each workstation are conveyed to a required workstation by a belt conveyor or a cart. Also, assembly of parts at each workstation,
Operations such as adjustment and inspection are performed on a belt conveyor or on a work table provided on a side of the belt conveyor. According to such a belt-coveyer type production line, it is possible for the workers deployed at each workstation to efficiently perform relatively simple tasks assigned to each workstation, thereby improving productivity. It is.

[0003]

However, there are the following problems in a belt conveyor type production line. In the case of a production line including many workstations, a space for installing a belt conveyor for connecting these workstations is large, and a large floor area is required. In particular, the transport path of the belt conveyor must basically be configured as a straight route, and since the belt conveyor cannot be arranged crossing on the same plane, extra space is required. .

When it is necessary to add a workstation or change a layout in accordance with a partial change of the production line, it is necessary to change the arrangement of the belt conveyor at the same time, which requires a great deal of labor and cost. Required.

When assembling a plurality of types of products on the same line, different components are mixedly supplied for each product to each workstation, so that an operator needs to carefully select components of a target product. In some cases, parts of other products may be erroneously assembled.

[0006] Since the workers deployed in each workstation are basically required to faithfully perform only the work assigned to each workstation, the work content becomes monotonous, and the production efficiency and quality may be reduced. . Further, if the work is stopped at any of the workstations, the effect directly leads to a reduction in production efficiency. Here, even if workers at other workstations do not support, it is normal that one workstation does not have parts and tools for two people. You will be waiting.

On the other hand, a one-line system has been proposed in which one product is assembled by one worker on one work table. According to this method, it is easy to relocate or change production equipment, and since skilled workers perform relatively complicated work in a patterned manner, compared to the simple work divided into labor by the belt conveyor system. It is expected to improve production efficiency and quality.

However, the one-line system has a limitation in the number of lots and types of parts that can be supplied to one workbench, and cannot cope with an increase in the number of lots and types. Needless to say, supply of parts to the work table and unloading of the product rely on manual work using a hand cart and the like, so there is also a problem in logistics.

An object of the present invention is that the physical distribution is better than the one-line system, and it is easy to cope with an increase in the number of lots and types, and the production line can be easily changed as compared with the belt conveyor system. In addition, a new type of production system that can reduce the installation space and improve production efficiency and quality, and a self-propelled work center that is indispensable for constructing the production system It is to provide.

[0010]

A self-propelled work center according to the present invention is provided with a parts storage shelf (3) and a work table (3) on a traveling vehicle (2) to be self-propelled along a predetermined track. 4) is attached.

More specifically, the component storage shelf (3) is configured by installing component trays (33) on each of tray support mechanisms arranged in a plurality of upper and lower stages, and is mounted on the component storage shelf (3). Work table (4)
Is attached.

The tray support mechanism includes a pair of left and right tray support arms (32) for supporting the component tray (33) in the front-rear direction orthogonal to the traveling direction of the traveling carriage (2). I have. More specifically, a turntable (41) is provided on the worktable (4).

The production system according to the present invention provides a floor (1) from a parts supply station to a product unloading station.
0) A guide line (11) extending above, a plurality of self-propelled work centers (1) self-propelled on the floor (10) along the guide line (11), and a plurality of self-propelled work centers. Work center (1)
And a control device for integrally controlling the traveling of the vehicle. The self-propelled work center (1) has a parts storage shelf on a traveling cart (2).
(3) and a work table (4)
(11) One self-propelled work center (1) stopped above constitutes one workstation.

Specifically, one or a plurality of work stations for assembling, adjusting, or inspecting parts are provided between the parts supply station and the product unloading station.

The guide line (11) also includes a return line extending from an exit of at least one workstation to a repair station. More specifically, the parts storage shelf (3) of the self-propelled work center (1) has a space for accommodating all parts required for assembling one product or semi-finished product.

[0016]

[Function] On the floor (10) inside the factory, there is a guide line (11) from the parts supply station to the product unloading station.
The traveling trolley (2) of the self-propelled work center (1) travels on the guidance line (11) from the component supply station to the product unloading station under traveling control by the control device. First, at the parts supply station,
After all parts necessary for assembling one product or a semi-finished product are loaded into the parts storage shelf (3) of the self-propelled work center (1), the traveling vehicle (2) starts self-propelled. In addition, tools required for assembling products are loaded on the component storage shelf (3) of the self-propelled work center (1) as needed.

Thereafter, the self-propelled work center (1) is stopped at a predetermined position where the worker waits by the traveling control by the control device, and this position becomes a work station, and the parts are assembled. Here, in the parts storage shelf (3) of the self-propelled work center (1), all the parts required for the work station are loaded, and no parts of other products are loaded. The operator may unconsciously take out the parts on the parts storage shelf (3) and assemble them on the worktable (4).

The parts to be incorporated in the workstation are not limited to a single part, but rather, plural kinds of parts are incorporated by one worker on the same workbench (4). In the workstation, not only assembling of parts but also adjustment and inspection work are sequentially performed by the same operator on the same work table (4) as necessary.

In the configuration in which the component trays (33) are installed in each of the tray support mechanisms arranged in a plurality of upper and lower stages, the component trays (3
3) Parts can be stored in groups for each.
Also, a large number of components can be compactly accommodated in the space between the traveling vehicle (2) and the work table (4).

In a configuration in which each tray support mechanism includes a pair of left and right tray support arms (32), (32) a component tray (33) in which components required for the work station are stored.
Is pulled out to the near side, and the other component tray (33) that gets in the way is slightly retracted, thereby making it easy to take out the target component. Further, the turntable (4) is placed on the worktable (4).
In the configuration provided with 1), the direction of the parts on the turntable (41) can be arbitrarily changed, and the work becomes easy.

Further, the self-propelled work center (1)
Move to the next worker's standby position,
A subsequent workstation is configured. Similarly, at the workstation, one or more operations are sequentially performed.

If a workstation for adjustment or inspection is configured, the guide line (11) comprises a return line extending from the exit of the workstation to the repair station, where the work station (4) is located. When a defect is found in the semi-finished product on the work table (4), the self-propelled work center (1) moves to a repair station via a return line, and the semi-finished product on the work table (4) is repaired.

The self-propelled work center (1) is connected to the guidance line (1).
1) When all work is completed through the above-mentioned predetermined number of workstations, the self-propelled work center (1) runs to the product unloading station,
(4) The above product is carried out.

[0024]

According to the present invention, the self-propelled work center (1) is composed of a traveling vehicle (2), a component storage shelf (3) and a work table (4).
When the production line is constructed, the guide line (11) simply extends around the desired route, and the conventional belt conveyor and the component storage shelves that should be permanently installed in each work station are used. In addition, a work table is not required. This significantly reduces the installation space on the production line. Also, just replace the guide line (11),
Since the movement route of the self-propelled work center (1) can be easily changed, it is possible to flexibly cope with the addition of a workstation or a change in layout.

The parts are transported by a self-propelled work center.
Since all the operations are performed by the traveling cart (2) of (1), the physical distribution is good. Also, by arranging a plurality of self-propelled work centers (1) on the guidance line (11) and operating them simultaneously, it is possible to easily cope with an increase in the number of lots,
Of course, by loading parts of different products for each self-propelled work center (1), it is possible to flexibly cope with an increase in types.

The work at one workstation constituted by one self-propelled work center (1) is as follows:
In addition to the work of assembling multiple types of parts, adjustment and inspection work are also included as necessary, so the work is not monotonous, and the production efficiency and quality are dramatically increased with the improvement of the skill of the workers To be improved. Needless to say, the parts necessary for assembling one product are the parts storage shelves of one self-propelled work center (1).
Since all parts are stored in (3), there is no danger of assembling parts of other products by mistake.

Furthermore, there is only a guide line (11) on the floor (10) between the plurality of workstations, and the worker can move freely across the guide line (11). Therefore, when work is stopped at one workstation, workers arranged before and after surround the self-propelled work center (1) of the workstation to assist the stagnated work. You can do it. Here, since all parts and necessary tools are loaded on the parts storage shelf (3) of the self-propelled work center (1), the assistance of other workers becomes effective. by this,
Even if work is stopped at one workstation, the production speed will recover quickly.

[0028]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below in detail with reference to the drawings. Self-propelled work center according to the present invention (1)
As shown in FIGS. 1 to 3, a component storage shelf (3) is mounted on a traveling vehicle (2) to be self-propelled along a guide line (11), and is mounted on the component storage shelf (3). The work table (4) is attached. An obstacle detection sensor (29) for avoiding collision with another self-propelled work center (1) traveling in front and other obstacles is attached to the front of the traveling cart (2). .

The parts storage shelf (3) is provided with a vehicle body (2) of the traveling vehicle (2).
A pair of left and right tray support arms (32) and (32) are attached to the two columns (31) and (31) standing upright on the upper and lower three stages, respectively, to accommodate and support the three component trays (33). It is possible. The worktable (4) has a turntable equipped with a lock mechanism (42).
(41) is attached, and the posture of the work (9) on the turntable (41) can be oriented in an arbitrary direction and locked in that posture.

A transceiver (6) having an antenna (61) is attached to the prop (31) on the traveling direction side for communication with a host computer described later. On the other side of the column (31), an input key group (7) for the worker to instruct the destination of the self-propelled work center (1), and the start of the self-propelled work center (1), Start button (7
1) and a stop button (72), and a display (70) for displaying various messages urging the operator to perform key operations.

As shown in FIG. 3, the depth length W of the tray support arm (32) is formed larger than the depth length B of the component tray (33). To take out the parts tray, pull out the parts tray (33b) as shown by the chain line, and
By retreating (33a) as shown by the dashed line, it is easy to take out the parts.

As shown in FIG. 4, the traveling vehicle (2) has a vehicle body (2).
At the bottom of (0), a pair of left and right driving wheels (21) (22) and a pair of left and right casters (28) (28) are provided, and the right driving wheel (21) has a right motor (23),
A left motor (24) is connected to the left driving wheel (22). Behind these motors (23) (24), batteries (25) (2
5) is installed.

Also, the casters (28) (28) and both motors (23) (2
During 4), the control of the self-propelled work center (1) itself,
An electric circuit box (50) for controlling communication with the host computer is provided. Caster (28) (28)
In front of the building is a guide line (1
A main magnetic sensor (26) for detecting 1) and an auxiliary magnetic center (27) for detecting a passage recognition marker (12) installed at a key point on the floor are mounted on one side.

FIG. 5 shows a configuration of a main circuit provided in the electric circuit box (50). The above-mentioned transceiver (6) having an antenna (61) is provided with a transmission circuit (62) and a reception circuit (63), and these circuits (62) and (63) are each composed of a main control comprising a microcomputer. It is connected to the output port and input port of the circuit (5).

The above-mentioned main magnetic sensor (26) and auxiliary magnetic center (27) are connected to the input port of the main control circuit (5) via a displacement detection circuit (51) and a counter circuit (52), respectively. ing. The right motor (23) and the left motor (24) are connected to output ports of the main control circuit (5) via driver circuits (53) and (54), respectively. Further, the input key group (7) is connected to an input port of the main control circuit (5).

The main magnetic sensor (26) is connected to the guide line (1).
It detects the left and right balance of the magnetic field lines received from 1),
The detection signal is sent to the displacement detection circuit (51), whereby the left and right displacement of the traveling vehicle (2) is detected. Information indicating the displacement is supplied to the main control circuit (5). The auxiliary magnetic center (27) detects magnetic lines of force received from the passage recognition marker (12), and the detection signal is sent to the counter circuit (52), whereby the traveling vehicle
The number of the pass recognition markers (12) passed by (2) is counted. The count value is sent to the main control circuit (5) and used for recognizing the current position of the self-propelled work center (1).

When the traveling control signal sent from the host computer is detected by the receiving circuit (63) of the transceiver (6), the detection signal is supplied to the main control circuit (5), and based on this, Then, control signals for starting, stopping, turning right and turning left of the self-propelled work center (1) are created and sent to the driver circuits (53) and (54). In the case of starting and stopping,
Both motors (23) and (24) are started and stopped at the same time, and in the case of right turn and left turn, a difference is given to the rotation speed of both motors (23) (24).

Thus, the self-propelled work center (1)
Travels along the guidance line (11)
If (2) is shifted left or right from the guidance line (11), this is detected by the position shift detection circuit (51), and the main control circuit
(5) uses a driver signal (5
3) Send to (54). The command of the destination workstation given to the main control circuit (5) by the operation of the input key group (7) and the count value inputted to the main control circuit (5) from the counter circuit (52) are transmitted. The signal is transmitted from the circuit (62) to the host computer. In response, the host computer creates a travel control signal for controlling travel of the self-propelled work center (1) and sends it back to the self-propelled work center (1).

FIG. 6 shows an example of the configuration of a production line for a liquid crystal projector using the self-propelled work center (1). The guiding line (11) includes a parts supply station (8), a parts assembly station (81), a first adjustment station (82), a second adjustment station (83), a third adjustment station (84), and a cabinet mounting station (85). ) And the inspection station (86), and are stretched vertically and horizontally, and the guidance line (11) is connected to each adjustment station (8).
2) Includes a return line that extends from the exit of (83) (84) to the semi-finished product processing station (87).

The component supply station (8) is provided with a component loading elevator (13) for loading components from a component warehouse provided on another floor, and is provided at an exit of the component loading elevator (13). Is connected to a conveyor (15), and a dust remover (14) is provided in the middle of the conveyor (15).

From the parts warehouse, the parts trays (33) containing the parts are stacked on the conveyor (15) in a state of being stacked in three stages at four corners via spacers (34) as shown in FIG. It is supplied and passes through the dust removing device (14) in this state. Here, since the three-stage component trays (33) are stacked at a sufficient interval from each other, the cleaning air in the dust removal device (14) flows through the corners of the components, and the dust removal efficiency is high. Become.

At the parts supply station (8) shown in FIG. 6, the parts storage shelf (3) of one self-propelled work center (1)
After all the parts necessary for assembling one product are loaded, the self-propelled work center (1) starts moving to the parts assembly station (81) along the guidance line (11). I do. In the parts assembling station (81), the self-propelled work center (1) temporarily stops, and in a stopped state, all parts are assembled. Then, the first adjustment station (82),
Second adjustment station (83) and third adjustment station
After (84), the adjustment of the optical system and the like is performed.

When any defect is found in the adjustment process, the operator operates the input key group (7) to cause the self-propelled work center (1) to send the semi-finished product processing station (87). ). As a result, the self-propelled work center (1) returns to the semi-finished product processing station (87) along the return line. Defective products are picked up at the semi-finished product processing station (87), repaired at a repair station (not shown), and mounted again on the work table (4) of the self-propelled work center (1). When the operator operates the input key group (7) and designates the workstation to be moved next, the self-propelled work center (1) proceeds toward the workstation.

The self-propelled work center (1) having passed through the third adjustment station (84) returns to the parts supply station (8) once with the adjusted semi-finished product mounted thereon, and supplies the cabinet here. After receiving, proceed to cabinet mounting station (85). Then, after the cabinet is attached at the station (85), the process proceeds to the inspection station (86). Here, the product on the self-propelled work center (1) is transferred from the self-propelled work center (1) to the product unloading elevator (19) after undergoing a final inspection such as a pressure resistance test, and other products are transferred therefrom. It is carried out to the product warehouse on the floor.

FIG. 7 shows an operation on a production line using the self-propelled work center (1). A plurality of self-propelled work centers (1) are arranged on a guidance line (11) stretched on the floor (10), and each self-propelled work center is installed in the control room (16). A host computer (17) and a transceiver (18) for controlling the running of all self-propelled work centers (1) are installed by bidirectional communication with (1).

One self-propelled work center stopped at a predetermined position under running control by the host computer (17)
One workstation is configured by (1), and basically, the workstations are arranged by the number of stopped self-propelled work centers (1).
In addition, at the adjustment station, beside the guidance line (11),
Necessary equipment for adjustment is provided.

At each workstation, work such as assembly and adjustment is performed by a worker.
All necessary parts can be taken out from the parts storage shelf (3) of the self-propelled work center (1), and these parts can be assembled on the worktable (4). At this time, since the parts storage shelf (3) does not contain parts of other products, no assembly error occurs. When assembly is completed,
Since there should be no parts left in (3), this check guarantees error-free assembly.

On the floor (10), only the guide line (11) and the passage recognition marker (12) are stuck on the floor, and the worker can freely cross the guide line (11). Because it is possible to move, it is easy to support other work stations where work is stagnated. At this time, since a plurality of workers can surround the self-propelled work center (1) of the workstation and assist the work, even if a stagnation occurs, the subsequent recovery is quick. .

It is also possible to stop the self-propelled work center (1) at an arbitrary position on the guide line (11) and use the position as a new workstation to operate the original production line irregularly. It is. Even in this case, the self-propelled work center (1) accommodates the necessary components in the component storage shelf (3) and naturally includes the work table (4). Do not need.

Of course, since there is no belt conveyor between the workstations, the visibility is good and the progress of the work at each workstation can be easily grasped visually, which is convenient in the process management.

Further, when it is necessary to partially or completely change the production line, it is possible to flexibly respond to the layout change only by changing the route of the guide line (11). It is not necessary to relocate the belt conveyor or move the stationary work table.
Also, when designing the route of the guide line (11), branching, alternating current, and crossing of the guide line (11) can be performed freely, which increases the degree of freedom in layout compared to the conventional belt conveyor system. In addition, the installation space for the equipment is greatly reduced.

The description of the above embodiments is for the purpose of illustrating the present invention, and should not be construed as limiting the invention described in the claims or reducing the scope thereof. Further, the configuration of each part of the present invention is not limited to the above-described embodiment, and it is needless to say that various modifications can be made within the technical scope described in the claims. For example, in the above-described embodiment, three types of work stations of assembly, adjustment, and inspection are configured between the component supply station and the product unloading station.
It is also possible to perform these operations collectively on one workstation, in which case the guidance line (11)
It extends from the parts supply station to the product unloading station via a single work station.

[Brief description of the drawings]

FIG. 1 is a perspective view of a self-propelled work center according to the present invention.

FIG. 2 is a side view of a self-propelled work center.

FIG. 3 is a front view of a self-propelled work center.

FIG. 4 is a rear view of the self-propelled work center.

FIG. 5 is a block diagram showing a main circuit configuration of the self-propelled work center.

FIG. 6 is a diagram illustrating a configuration example of a production line using a self-propelled work center.

FIG. 7 is a perspective view showing a state of work in the production line.

FIG. 8 is a perspective view showing a main part of the component supply station.

[Explanation of symbols]

 (1) Self-propelled work center (2) Traveling trolley (3) Parts storage shelf (31) Post (32) Tray support arm (33) Parts tray (4) Work table (41) Turntable (6) Transceiver ( 61) Antenna (7) Input key group (9) Work (11) Guidance line (12) Marker for passage recognition

Claims (5)

(57) [Claims] 1. A guide line (11) extending on a floor (10) from a parts supply station to a product unloading station.
And a plurality of self-propelled work centers (1) self-propelled on the floor (10) along the guidance line (11), and a general control of traveling of the plurality of self-propelled work centers (1). The self-propelled work center (1) includes a parts storage shelf (3) and a work table (4) on a traveling vehicle (2) to be self-propelled along a guidance line (11). The component storage shelf (3) is configured by installing component trays (33) in each of tray support mechanisms arranged in a plurality of upper and lower stages, and the tray support mechanism runs on the component tray (33). A pair of left and right tray support arms (32) (32) that are movably supported in the front-rear direction orthogonal to the traveling direction of the cart (2), and the depth length A of the tray support arms (32) (32) Is formed so as to be longer than the depth B of the component tray (33), the work table (4) is mounted on the component storage shelf (3), Production systems using self-propelled work center one workstation by emissions (11) one self-propelled work center that has stopped on (1) is characterized in that it is configured. 2. The production system according to claim 1, wherein a turntable (41) is mounted on the worktable (4). 3. The production system according to claim 1, wherein one or a plurality of work stations for assembling, adjusting, or inspecting parts are configured between the part supply station and the product unloading station. 4. The production system according to claim 3, wherein the guide line (11) comprises a return line extending from an outlet of at least one workstation to a repair station. 5. A parts storage shelf of a self-propelled work center (1).
The production system according to any one of claims 1 to 4, wherein (3) has a space for accommodating all parts necessary for assembling one product or a semi-finished product.