JP4657994B2 - Component unloading apparatus and component unloading method from rack center - Google Patents

Description

  The present invention relates to a component carrying-out apparatus and a component carrying-out method from a rack center that temporarily stores components supplied to a production line such as a vehicle body assembly line.

  Conventionally, when supplying assembly parts to be assembled in an assembly production line such as an engine assembly line of an automobile, for example, a large number of parts shelves are provided to store incoming parts along the assembly line. Various parts necessary for all types of workpieces flowing through the assembly line are stored on the shelf, and the operator sequentially selects and removes the necessary components from the component shelf according to the flowing workpiece, and then assembles them to the workpiece. It is common.

Here, various contrivances for more accurately supplying assembly parts to such an assembly production line have been made, for example, each storage section of a component storage shelf placed on a pallet truck of an automated guided vehicle There is disclosed a photoelectric sensor that is provided with a photoelectric sensor to detect that a part has been put in and out of each storage unit.
By the way, in recent years, for example, in an assembly production line such as an engine assembly line of an automobile, it is required to be a so-called mixed flow line in which various types of workpieces are assembled and produced on the same line in response to diversification of user's preference. ing. In such a mixed flow line, normally, many types of workpieces flow in an irregular order that is not organized by type or model, for example, in order of delivery (for example, Patent Document 1).
JP 2000-203705 A

  Therefore, when carrying out the parts assembled in such an assembly production line from the parts shelf, it is necessary for the worker to carry out the parts from the parts shelf in an unordered and irregular order for each type or model. There is a problem that is complicated. In addition, since it is necessary to sequentially pick out parts that have been carried out in such an irregular order from the parts shelf for workpieces of different models each time, work efficiency is poor and work mistakes are likely to occur. There was a problem.

  Accordingly, an object of the present invention is to be able to reliably carry out delivered parts in order from a rack center and supply the parts from the rack center to a production line.

In order to achieve the above object, the invention described in claim 1 is arranged corresponding to a production line of a product produced based on a production plan (for example, production line 1 in the embodiment), and is carried in from a parts manufacturer. The box (for example, the box 6 in the embodiment) containing the parts to be assembled in the production line is received based on the code information (for example, the barcode in the embodiment), and is carried out in the assembling order based on the production plan. A component carry-out device from a rack center (for example, the rack center 4 in the embodiment) provided with possible component shelves (for example, the component shelf 8 in the embodiment). A production plan in which a plurality of storable component shooters (for example, the component shooter 9 in the embodiment) are provided and the data of the production plan is stored. Data storage unit (for example, production plan data storage unit 20 in the embodiment) and parts assembly stations of the production line according to the production plan based on the production plan data (for example, part assembly station S in the embodiment) An order setting unit (for example, the order setting unit 40 in the embodiment) that sets the order that can be carried out, and a box setting status confirmation unit (for example, the box in the embodiment) that grasps the arrangement status of the box in each component shooter. An unloading part instructing unit (for example, an unloading part instructing unit in the embodiment) that instructs how many parts in the unloading box on the unloading side of which part shooter should be unloaded based on the order setting unit 45) and an unloading part confirmation unit (for example, unloading part confirmation unit 46 in the embodiment) for confirming unloading of the part in the pass box in which the part is accommodated. With the door, when a plurality of parts shelves in the rack center is located, the discharge part instruction section and parts shelf unloading of parts is the highest priority, then the component shelf unloading of parts is prioritized It is characterized by instructing .
By configuring in this way, multiple parts shooters capable of storing multiple boxes in the depth direction are provided on the parts shelf, and parts are assembled according to the production plan based on the production plan by the order setting unit. Set the order in which the parts can be unloaded, confirm the unloading of the parts in the box containing the parts by the unloading parts confirmation unit, and grasp the layout of the boxes in each part shooter by the box placement status confirmation unit. Based on the order set by the order setting unit, the carry-out component instructing unit can instruct how many parts of the passing box on the carry-out side of which component shooter are to be carried out.
In addition, it is possible to grasp the parts shelf that needs to be carried out immediately and the parts shelf that needs to be carried out next.

In the invention described in claim 2, when the carry-out component instructing unit confirms that the carry-out of the component for which the carry-out instruction has been issued is completed from the component shooter, A part shooter is designated and the number of parts to be carried out is designated.
With this configuration, it is possible to grasp the number of the part shooter and the part in which the part to be carried out next is stored by the carry-out part instruction unit.

The invention described in claim 3 is characterized in that the carry-out part instruction unit instructs how many parts are to be carried out as the whole parts shelf.
By comprising in this way, the carrying-out components instruction | indication part can grasp | ascertain how many components are carried out as the whole components shelf.

In the invention described in claim 4 , the code information includes a box that is arranged corresponding to the production line of the product produced based on the production plan and contains the parts that are carried in from the parts manufacturer and assembled in the production line. A method for carrying out a part from a rack center having a parts shelf having a plurality of parts shooters that can be taken out in the order of assembly based on a production plan, wherein a plurality of the boxes are stored in the parts shelf in the depth direction. A plurality of possible part shooters, and an order setting step for setting an order in which the parts can be carried out to each part assembly station of the production line according to the production plan based on the production plan; The unloading part confirmation process for confirming the unloading of parts, the through box placement status confirmation process for grasping the layout status of the through boxes in each part shooter, and the order setting process If any parts Kayoibako components in the carry-out side of the chute includes a many pieces unloading parts instruction step of instructing whether to discharge a plurality of parts shelves in the rack center is arranged based on the order set by the In addition, the unloading part instruction unit is configured to instruct a parts shelf where priority is given to the unloading of parts and a parts shelf where priority is given to the unloading of parts .
With this configuration, the order setting process sets the order in which the parts can be carried out to each part assembly station of the production line based on the production plan based on the production plan, and the parts are stored in the unloading part confirmation process. While confirming the delivery of the parts in the box, grasping the placement situation of the passing boxes in each part shooter in the box placement status confirmation process, and on the part shooter delivery side based on the order set in the order setting process It is possible to instruct how many parts of a certain box are to be carried out in the carry-out part instruction step.

According to the first aspect of the invention, the order setting unit sets the order in which parts can be carried out to each part assembly station of the production line based on the production plan based on the production plan, and the parts are accommodated by the carry-out part confirmation unit. The component shooter is checked based on the order set by the sequence setting unit while confirming the carrying-out of the components in the box, and grasping the placement state of the box in each component shooter by the box arrangement status confirmation unit. The unloading part instruction unit can instruct how many parts of the box on the unloading side to be unloaded, so it is possible to smoothly and accurately pass through boxes containing parts of different models according to the production plan. There is an effect that can be carried out in order to the assembly station.
In addition, since it is possible to grasp the parts shelves that need to be immediately unloaded and the parts shelves that need to be unloaded next, it is possible for the workers to take out even though the unloading operation is set. Therefore, it is possible to suppress the take-out operation from only the component shelves that is convenient for the parts, and it is possible to carry out the parts without deviation from the respective component shelves.
According to the invention described in claim 2, since the number of parts shooter and the number of parts in which the parts to be carried out next are stored can be grasped by the carry-out parts instruction unit, the parts can be carried out accurately and easily. There is an effect that can be done.
According to the invention described in claim 3, since it is possible to grasp how many parts are to be carried out as the whole parts shelf by the carry-out parts instructing unit, it is possible to facilitate the parts carrying out management as the whole parts shelf. There is an effect that the parts can be easily carried out.
According to the invention described in claim 4 , the order in which the parts can be carried out to each part assembly station of the production line according to the production plan is set based on the production plan by the order setting process, and the parts are accommodated by the carry-out part confirmation process. While confirming the delivery of the parts in the box, check the placement status of the boxes in each part shooter in the box placement status confirmation process and check the parts shooter's status based on the order set in the order setting process. In the unloading part instruction process, it is possible to instruct how many parts in the unloading box are to be unloaded, so that the unloading box containing parts of different models can be smoothly and accurately set up according to the production plan. There is an effect that it can be carried out in order to the assembly station.

Next, embodiments of the present invention will be described with reference to the drawings.
(Parts supply system to production line)
As shown in FIGS. 1-3, the production line 1 is a production line for assembling the vehicle body 2 of the motor vehicle as a product. While conveying the vehicle body 2 placed on the conveyor 3, a plurality of parts are assembled by an operator beside the conveyor 3 at each component assembly station S. Here, the production line 1 is a mixed flow line in which a plurality of types of vehicle bodies 2 are mixedly produced in units of lots based on a production plan planned according to an order.

  In a part of the area where the production line 1 is installed, a rack center 4 is provided in a place slightly away from the production line 1 (not beside the production line 1). A truck 5 shipped from a parts manufacturer and loaded with parts is carried into the rack center 4, and a cart 6 containing parts assembled in the production line 1 is loaded on the truck 5. Yes. A bar code label L, which will be described later, is stored in the pass box 6 and information stored in each part maker is pasted. The bar code printed on the bar code label L is read by the bar code reader 7 to produce each part. Corresponds to the plan. Here, for example, when the day is divided into four or eight parts, the parts used for production are stored in the pass box 6.

As shown in FIGS. 2 and 3, the rack center 4 has component shelves 8, 8,... Arranged in a plurality of areas E1 to E3. Here, casters Q are attached to these component shelves 8, and each component shelf 8 is movably mounted, and is wired to a vehicle body assembly host computer 10 described later and other component shelves 8 via connectors R. Connected by. With this configuration, the layout of the component shelves 8 in the rack center 4 can be freely changed, so that it is possible to flexibly cope with an increase or decrease in the types of vehicles flowing through the production line. A transceiver may be used instead of the wiring and the connector R.
The component shelf 8 includes a plurality of component shooters 9 capable of storing the box 6 in which components are stored in the depth direction. The component shooters 9 are provided in 12 rows in total in four rows in the width direction, ie, the upper, middle, and lower three stages. Each component shooter 9 is configured as a carry-in side for carrying in the through box 6 on the front side, and a carry-out side for taking out the components in the pass box 6 on the near side, and the component shooter 9 is inclined from the carry-in side toward the carry-out side. When the pass box 6 is put into the parts shooter 9, the box automatically moves to the carry-out side, and the pass box 6 is carried into the carry-out side in order from the carry-in side.

  As shown in FIG. 2, an instruction lamp A is provided at the upper part of the frame on the carry-in side of each component shelf 8 so that the part number and the color number corresponding to the pass box 6 to be loaded next are lit and displayed. It has become. In addition, an instruction lamp B is provided at the upper part of the frame of each component shooter 9, and the component shooter 9 into which the target pass box 6 is to be carried is indicated by lighting. A button C is provided on the side of the instruction lamp B, and when it is pressed when the instruction to carry in the designated box 6 is finished, the vehicle body assembly host computer 10 confirms this and then carries The component information of the through box 6 to be displayed is displayed on the instruction lamp A.

  As shown in FIG. 3, an instruction lamp D is provided at the upper part of the frame on the carry-out side of each component shelf 8, and the vehicle body number, the component number, and the color number corresponding to the next component to be carried out are lit and displayed. It has become. An instruction lamp E is provided at the upper part of the frame of each component shooter 9 so that the number of components to be taken out next is lit and displayed. Further, an instruction lamp F is provided on the frame side portion of the parts shelf 8 so that the total number of parts of the parts shelf 8 to be taken out to the transport pallet 14 of the transport cart 12 this time is lit and displayed. In addition, as shown in FIG. 3, the conveyance pallet 14 is provided with several partitions inside according to components.

  Here, the instruction lamp E is provided with a button G. When the button G is pressed every time one part is taken out, the number of the indicator lamp E and the indicator lamp F is subtracted. In addition, the instruction lamp F is provided with a button H. This button H is for transmitting completion of unloading to the vehicle body assembly host computer 10 when pressed when the total number becomes zero. Here, when the number displayed on the instruction lamp F becomes zero, the vehicle body assembly host computer 10 changes the display color of the instruction lamp F to notify the operator that the operation of carrying out to the transfer pallet 14 is completed.

  Here, both the delivery of the passing box 6 to the carry-in side of the parts shooter 9 and the delivery of the parts in the pass box 6 located on the carry-out side of the parts shelf 8 are both specified based on the product production plan in the production line 1. The parts shooters 9 are set in three storage formats for how to store the parts.

  The first format is a fixed format, in which the component shooter 9 is set exclusively for a specific component. When the part shooter 9 is filled with the pass box 6 storing the same parts, the remaining pass box 6 storing the same parts is placed in a state of being loaded on the floor on the carry-in side of the part shooter 9. This format is used as a component shooter 9 that targets only the same color when there are many differently colored components that are difficult to distinguish. This is because it is difficult to discriminate the parts (different colors) if the same box shooter 9 is lined up with the box 6 containing parts with slightly different colors. This format is applied to car body skin parts of models with slightly different colors and many car body colors.

  Further, the second type is a simple variation type, and when the pass box 6 in which the same parts are stored does not fit into one part shooter 9, do not place it on the floor. It is housed in the parts shooter 9. Here, when carrying the box 6 into the parts shooter 9 depending on the storage type, the box passes through the middle stage, the upper stage, and the lower stage below the middle stage where the working posture is least difficult. 6 carry-in position is set. Thereby, the posture burden of the operator can be reduced as much as possible.

  The third format is a component shooter 9 set as a variable permutation format. Fluctuation means that the parts carried into the same part shooter 9 are different, and is a form in which the pass boxes 6 containing different parts are randomly arranged in the order of delivery. By arranging the boxes 6 from the carry-out side in the order of the production plan, this type can always fill the parts shooter 9, that is, the parts shelf 8 with the boxes 6, so that storage space can be saved and the rack center 4 can be saved. The occupation area for the whole factory can be minimized. Each component shelf 8 is basically set around the component shooter 9 set as the variation permutation format. However, as described above, the special component is set to the fixed format or the simple variation format. The part shooter 9 is set as a part. Here, if all the component shooters 9 are set to the variable permutation format, it is advantageous in that the through box 6 can be stored in the component shooter 9 without empty space.

  As shown in FIGS. 1 and 3 to 6, a self-propelled transport carriage 11 is movably disposed between the vicinity of the component shelf 8 of the rack center 4 and each component assembly station S. This self-propelled conveyance cart 11 is constituted by a conveyance cart 12 and a self-propelled vehicle 13, and these are connected so as to be connectable and separable. The self-propelled vehicle 13 is provided with a locking portion 13 a that engages with a V-shaped locking plate 13 b provided in the plan view provided on the conveyance carriage 12, and the self-propelled vehicle 13 enters the lower side of the conveyance carriage 12 from the rear side. When the locking portion 13a of the self-propelled vehicle 13 protrudes and locks to the locking plate 13b of the transport carriage 12, the two travel together and automatically travel to the target location. On the other hand, when separating the both, the locking portion 13a of the self-propelled vehicle 13 is immersed downward to release the locked state of the conveying cart 12 with respect to the locking plate 13b, so that the self-propelled vehicle 13 is separated from the conveying cart 12. Do this by getting out.

  The transport carriage 12 is provided with an upper shelf 16 on which a plurality of transport pallets 14 can be placed, and a lower shelf 17 on which an empty transport pallet 14 can be placed. Here, unillustrated transport rollers are pivotally supported on the upper shelf 16 and the lower shelf 17. In the transport carriage 12 shown in FIG. 3, the upper shelf 16 is a component supply shelf that is inclined so as to be lowered in the carry-in direction, and the lower shelf 17 is collected so as to be inclined so as to be lowered in the carry-out direction. However, the upper shelf 16 and the lower shelf 17 may be horizontal as in the transport carriage 12 shown in FIGS. And the parts taken out from the box 6 located on the carry-out side of the parts shelf 8 are placed on the transport pallet 14 of the upper shelf 16 by the amount used in the predetermined parts assembly station S, When the necessary number of parts are stored in the transport pallet 14, the self-propelled vehicle 13 is locked to the transport cart 12 and moved to the target component assembly station S as the self-propelled transport cart 11.

Specifically, based on an instruction from the vehicle body assembly host computer 10, the self-propelled vehicle 13 moves on the forward track K <b> 1 from the standby area ET to the arrangement position of the transport carriage 12 located near the parts shelf 8. Here, the integrated self-propelled conveying cart 11 is connected to the conveying cart 12 and moves to the parts assembling station S via the branch start K2, and enters the return track K3, where the self-propelled vehicle is arranged. When 13 is separated from the transport carriage 12, the transport pallet 14 storing the parts of the upper shelf 16 of the transport carriage 12 is supplied to the parts assembly station S.
In addition, the transport pallet 14 that has been emptied by using the parts at the parts assembly station S is collected in the lower shelf 17 of the transport cart 12 that is waiting to be emptied by supplying the transport pallet 14 at the parts assembly station S. When the empty transport pallet 14 fills the lower shelf 17, the self-propelled vehicle 13 separated from the transport cart 12 and in the standby position travels on the return track K3 and is locked to the transport cart 12, and the vehicle body assembly host Return to the vicinity of the parts shelf 8 of the rack center 4 instructed by the computer 10. The self-propelled vehicle 13 returns to the standby area ET.

As shown in FIGS. 1 and 4, the parts assembly station S is provided with a transfer pallet supply / discharge table T. A transfer pallet 14 of the transfer carriage 12 is placed on the upper stage of the transfer pallet supply / discharge table T on the production line 1. A supply shooter 15 inclined to the front side to be slid and moved in the vicinity of the conveyor 3 is provided. The supply shooter 15 is configured such that its carry-in end can be connected to an upper shelf 16 of the carriage 12 separated from the self-propelled carriage 11, and the conveyance pallet 14 is prevented from dropping at the carry-out end. A fall prevention stopper ST1 is provided. The conveyance pallet 14 of the upper shelf 16 on the conveyance carriage 12 is supplied to the supply shooter 15 in a state where the upper shelf 16 of the conveyance carriage 12 and the supply shooter 15 are connected.
In addition, a discharge shooter 18 that is inclined rearward is provided at the lower stage of the conveyance pallet supply / discharge table T, and the conveyance pallet 14 that is empty after the parts are assembled to the vehicle body 2 on the supply shooter 15 is discharged by the operator. It is transferred to and accumulated. A movable stopper ST2 is swingably provided on the side of the discharge shooter 18 to which the conveyance carriage 12 is connected. In normal times, the movable stopper ST2 is in a suspended state to prevent the empty conveyance pallet 14 from falling. ing. Here, the supply shooter 15 and the discharge shooter 18 are pivotally supported by a conveyance roller (not shown). Then, with the lower shelf 17 of the transport carriage 12 and the discharge shooter 18 connected, the movable stopper ST2 is turned to the transport trolley 12 side to release the restriction, and the transport pallet 14 that has become empty becomes the discharge shooter 18. It is collected from above to the lower shelf 17 of the transport carriage 12. Here, the supply of the transfer pallet 14 from the transfer carriage 12 to the transfer pallet supply / discharge base T and the discharge of the empty transfer pallet 14 from the transfer pallet supply / discharge base T to the transfer carriage 12 are performed simultaneously. Further, the discharge shooter 18 may be disposed beside the supply shooter 15. 3 shows an example in which the upper shelf 16 and the lower shelf 17 are inclined as the transport carriage 12. However, as shown in FIG. 4, the upper shelf 16 and the lower shelf 17 are also in a horizontal state. It is the same.

(Body assembly host computer)
As shown in FIGS. 7 and 8, the vehicle body assembly host computer 10 is connected to a production management host computer SC that manages production plans in the automobile production lines L1, L2,. The production management host computer SC includes a production plan database SDS for storing production plans set according to orders and a parts table database BDS for setting and storing parts for each model. Set the parts to be ordered to and place an order with each parts manufacturer. In FIG. 7, “shipment results” and “acceptance results” indicate that the shipment results and the inspection results are transmitted and received as data between each component manufacturer and the automobile production line L1 via the production management host computer SC. It means to check each other in the form. Here, for example, in addition to the body assembly host computer 10, the automobile production line L1 is provided with a press host computer, a welding host computer, a painting host computer, and an engine host computer. Similarly, each host computer is a production management host computer SC. It is connected.
As shown in FIG. 8, the vehicle assembly host computer 10 is provided with a production plan data storage unit 20. Here, the production plan data storage unit 20 is production plan data in the production line 1 of the body assembly, and the latest one week of production plan data is transferred and overwritten every day from the production management host computer SC. The In FIG. 8, which will be described in detail below, the functions of the vehicle body assembly host computer 10 are expressed in blocks for easy understanding.

  The production plan data storage unit 20 stores the order status of each model and information about each part required according to the order status. As information on the order status, lot no. Information on destination, model, type, options, paint color, number of lots, number of units, etc. Information about each part means information such as a part number, a part name, and a color number. Further, the body assembly host computer 10 is provided with an order data storage unit 21 for storing order data ordered from the production management host computer SC to each component manufacturer. The ordering data stored in the ordering data storage unit 21 includes a part manufacturer, a factory name of the part manufacturer, a rack center name as a part delivery location, a part number, a color number, an order date / time, a quantity, a delivery date, and the like. . The order from the parts manufacturer is stored in the production plan database SDS and is ordered from the production management host computer SC while referring to the parts table database BDS based on the weekly production plan updated every day. The delivery date from the parts manufacturer is divided into four or eight days per day according to the distance from the automobile production line to the parts manufacturer factory, the size of the parts, the amount used per unit, etc. Put in 6 and have it delivered. At this time, in the box 6, there is a box 6 in which parts that cannot be continuously supplied to the production line 1 but that are housed in one box 6 and are carried on another occasion are stored.

As shown in FIG. 8, the vehicle body assembly host computer 10 is provided with a carry-in part confirmation unit 23 that confirms the carry-in of the parts in the pass box 6 carried into the rack center 4 by the cart 5 from the parts maker. The carry-in part confirmation unit 23 confirms whether or not a part has been delivered corresponding to the order data stored in the order data storage unit 21. Specifically, as described above, the cart 5 loaded with the parts carried from the parts maker is carried into the rack center 4 of the delivery destination factory. At this time, the bar code label L attached to the box 6 The barcode information is read by the barcode reader 7, and the code information is confirmed by the carry-in component confirmation unit 23 receiving the barcode information.
The shipment status from the parts manufacturer, that is, the code information of the shipped box 6 is received by the shipping list receiving unit 24 of the vehicle body assembly host computer 10 via the production management host computer SC, and this is sent to the carried-in part checking unit 23. The entry may be confirmed when the input box 6 arrives at the delivery destination factory.
Here, when it is found out that there are insufficient parts that should have been carried in the imported parts confirmation unit 23, that different parts have been carried in, or that too many parts have been carried in. Is provided with a notification unit 25 for outputting a warning to call attention to this.

  The vehicle body assembly host computer 10 includes a carry-in instruction unit 26 that gives an instruction for carrying the parts carried into the rack center 4 by the pass box 6 into the parts shooter 9 of the parts shelf 8 for each box 6. The parts carried into the rack center 4 are divided into four or eight parts per day, and are carried in at a time zone corresponding to this division, so that the carry-in is completed at an optimum time corresponding to the time to be assembled at the parts assembly station S. Is planned. Therefore, the carry-in time and the carry-in order to the parts shelf 8 are set according to the assembly timing of the parts assembly station S to which each part is supplied. Since the pass box 6 supplied from the carry-in side of the parts shelf 8 is sequentially taken out from the carry-out side of the parts shelf 8, the parts to be assembled at the next time must be arranged on the carry-out side of the parts shelf 8 as a result. There is. That is, the carry-in instruction unit 26 instructs which component shooter 9 the corresponding pass box 6 is to be put in such a manner that the next component used for assembly is positioned on the carry-out side of the component shelf 8 in this way.

  The vehicle body assembly host computer 10 includes a transfer instruction unit 27 that urges transfer of the components in the pass box 6 on the carry-out side of the component shooter 9 to the transport pallet 14 based on the production plan data. The parts used for the next assembly are stored in the pass box 6 located on the carry-out side of the parts shelf 8. Of the parts of each pass box 6, which one of the pass boxes 6 is transported first. The transfer time to the component assembly station S (the transfer time of the self-propelled transfer carriage 11) is determined based on when the supply destination of each component is assembled at which component assembly station S. It is necessary to take this into consideration. The parts taken out from the carry-out side of the parts shelf 8 and transferred to the transport pallet 14 are the parts that are required at the parts assembly station S earliest. Therefore, in order to seamlessly transport the next assembled parts to the parts assembly station S by the self-propelled transport carriage 11, the transfer instruction unit 27 transfers the parts of the box 6 of any part shooter 9 of the parts shelf 8. It is instructed whether to transfer to the transport pallet 14.

  The vehicle body assembly host computer 10 detects when a component is transferred to the transport pallet 14 of the transport cart 12 by the transfer instruction unit 27 and detects the self-propelled transport cart 11 having the transport pallet 14 as a transport destination. A carriage supply instructing unit 28 for giving an instruction to move to the component assembly station S is provided. In other words, the transport carriage 12 to be transported next to the parts assembly station S stands by at a part adjacent to each parts shelf 8, but the parts in the passing box 6 on the carry-out side of the parts shooter 9 of the parts shelf 8 are not. When the necessary number is transferred, the cart supply instructing section 28 transmits a signal to the self-propelled vehicle 13 to move the self-propelled vehicle 13 from the waiting area ET and to the locking plate 13b of the transport cart 12. The locking portion 13a protruding from the position is locked and moved to the component assembly station S along the forward path K1 as it is. When the self-propelled transport carriage 11 supplies the transport pallet 14 to the target parts assembly station S, it enters the return path K3 from the forward path K1 via the branch path K2, and is arranged in front of the parts assembly station S. Stop on the provided stop marker SM, and then the self-propelled vehicle 13 immerses the locking portion 13a in the self-propelled vehicle 13 to release the locked state with the locking plate 13b of the transport carriage 12, and then Only the transport carriage 12 moves to the standby marker TM and waits in a state where the locking portion 13a protrudes from the self-propelled vehicle 13 at the standby position downstream of the rack center 4.

  The vehicle body assembly host computer 10 includes a cart collection instruction unit 29. The transport cart 12 arriving at the target parts assembly station S is connected to the transport pallet supply / discharge platform T by an operator, the transport pallet 14 is supplied from the transport cart 12, the empty transport pallet 14 is recovered, and then Then, the operator moves the transport carriage 12 to engage the locking plate 13b of the transport carriage 12 with the locking portion 13a of the waiting self-propelling vehicle 13, and pushes the start button 13c of the self-propelling vehicle 13 By doing this, the carriage recovery instruction section 29 detects this push button operation and reaches the stop marker SM laid on the return path K3 in the vicinity of the parts shelf 8 that has sent the transport carriage 12 toward the parts assembly station S. Stop after moving. Next, the locking portion 13a of the self-propelled vehicle 13 is immersed in the self-propelled vehicle 13 to separate the transport carriage 12 from the self-propelled vehicle 13, and after separation, the self-propelled vehicle 13 is returned to the standby area ET. is there.

  Therefore, when the pass box 6 in which the parts are stored by the cart 5 is carried into the rack center 4 and the barcode of the bar code label L of each pass box 6 is read by the bar code reader 7, this is stored in the body assembly host computer 10. This is confirmed by the carry-in part confirmation unit 23. Next, the vehicle body assembly host computer 10 instructs the through boxes 6 to be sequentially loaded into the component shooters 9 of the respective component shelves 8 by the carry-in instruction unit 26 via the production plan data storage unit 20 and the order setting unit 40. Carry in the box 6 in order. At this time, the arrangement state of the box 6 in each component shelf 8 is confirmed by the box arrangement state confirmation unit 43.

After the carrying-in operation of the box 6 to the parts shelf 8 or in parallel with this carrying-in work, the parts are taken out from the parts shelf 8 and transferred to the transport pallet 14 of the transport carriage 12. This transfer is performed by instructing the parts shooter 9 to be transferred to the transfer instruction unit 27 via the production plan data storage unit 20 and the order setting unit 40 of the vehicle body assembly host computer 10. When it is confirmed by the transfer instruction unit 27 that the transfer of the parts to the transfer carriage 12 is completed, the self-propelled vehicle 13 is locked to the transfer carriage 12 by the carriage supply instruction unit 28 and integrated. The self-propelled transport carriage 11 is moved to the parts assembly station S which is the transport destination, and here, the pass box 6 is supplied to the supply shooter 15.
On the other hand, the transport pallet 14 that has already been supplied and has been emptied is placed on the transport cart 12. When this operation is completed, the vehicle body assembly host computer 10 uses the cart recovery instruction section 29 to wait for the self-propelled vehicle. The vehicle 13 is locked to the conveyance carriage 12 loaded with an empty conveyance pallet 14, and the integrated self-propelled conveyance carriage 11 is brought close to the parts shelf 8 that has sent the conveyance carriage 12 toward the parts assembly station S. After moving to the laid stop marker SM, it is stopped. Next, the locking portion 13a of the self-propelled vehicle 13 is immersed in the self-propelled vehicle 13 to separate the transport carriage 12 from the self-propelled vehicle 13, and after separation, the self-propelled vehicle 13 is returned to the standby area ET. is there.

(Part recognition device using barcode reader 7)
As shown in FIGS. 1, 2, and 8, the bar code reader 7 is a bar code label L of a part carried into a rack center 4 by a cart 5 from a parts maker, specifically, a box 6 in which the part is stored. Are read and transmitted to / from the vehicle body assembly host computer 10.
A plurality of bar code readers 7 are arranged at arbitrary locations in the rack center 4. When the pass box 6 is carried in by a cart 5 from a parts maker and the operator turns on the bar code reader 7 near him, The ID information stored in the memory is transmitted from the transmission unit 30 of the barcode reader 7 to the vehicle body assembly host computer 10. Here, the ID information is unique identification information of the barcode reader 7 stored in the memory. The vehicle body assembly host computer 10 includes a code reader identification unit 31 that receives the ID information transmitted from the barcode reader 7 and identifies the barcode reader 7 based on the ID information. Thereby, the barcode reader 7 to be used is specified.

  The vehicle body assembly host computer 10 includes a reading program transmission unit 32 that transmits a program for reading a barcode to the barcode reader 7 identified by the code reader identification unit 31. Here, since the barcode reader 7 enables a plurality of operations in addition to the general warehousing operation, the operator who operates the barcode reader 7 is about to read the body assembly host computer 10 from now on. An operation list information transmitting unit 33 that transmits operation list information for selecting an operation and a reading operation program that is a program for performing an operation selected from the operation list information by the barcode reader 7 are transmitted to the barcode reader 7. An operation program transmission unit 34 is provided. In addition to the general warehousing operation, the operation list information includes, for example, an all clear operation, which is displayed on the display unit 35 of the barcode reader 7.

The bar code reader 7 that has received the reading program for general warehousing by the receiving unit 36 uses the bar code corresponding to the part maker of the part to be read from the part maker list table in which the list of the part maker is described by the bar code. Is transmitted from the transmission unit 30 to the vehicle body assembly host computer 10.
The vehicle body assembly host computer 10 includes a component manufacturer receiving unit 37 that receives information about which component manufacturer the component to be read by the barcode reader 7, that is, a barcode corresponding to the manufacturer of the component to be read from now on. And a manufacturer data transmission unit 38 for transmitting the component manufacturer data related to the component manufacturer code received by the component manufacturer reception unit 37 to the barcode reader 7. The barcode reader 7 that has received the data transmitted from the manufacturer data transmission unit 38 at the reception unit 36 becomes the barcode reader 7 dedicated to the component manufacturer at this point.
When the barcode reader L, which has been affixed to each passing box 6 by the barcode reader 7 which has become a specific component manufacturer dedicated device, starts to read the barcode, the code information is stored in a vehicle body assembly which will be described later. This is input to the carry-in part confirmation unit 23 of the host computer 10. Each part is associated with a production plan.

  Therefore, when the pass box 6 is carried into the rack center 4 by the cart 5 and the operator picks up the nearby bar code reader 7 and turns on the power, the code reader identification unit 31 of the vehicle body assembly host computer 10 displays the bar code. The reader 7 is identified, and a program for reading a barcode from the reading program transmission unit 32 is transmitted to the barcode reader 7. In addition, since the operation list is transmitted from the operation list information transmission unit 33 of the body assembly host computer 10 to the barcode reader 7, operation lists such as “general warehousing operation” and “all clear operation” are displayed on the display unit 35. . When the operator selects “general warehousing operation”, the operation program transmission unit 34 of the vehicle body assembly host computer 10 transmits an operation program for “general warehousing operation” and a message prompting the manufacturer to select is displayed on the display unit 35. indicate.

  Then, when the operator reads the barcode corresponding to the component manufacturer of the part to be carried in from the list table in which the manufacturer list is described by the barcode by the barcode reader 7, the manufacturer data of the vehicle body assembly host computer 10 is read. The parts maker data relating to the necessary parts maker code is transmitted from the transmission unit 38. As a result, the barcode reader 7 becomes a reading terminal dedicated to the parts manufacturer, and the barcode reader 7 reads the barcodes of the barcode labels L of the respective boxes 6 that have been carried in. Information of the pass box 6, that is, all parts, is transmitted to the carry-in part confirmation unit 23 of the vehicle body assembly host computer 10.

(Parts carry-in device to the rack center)
As shown in FIGS. 2 and 8, the vehicle body assembly host computer 10 supplies parts to each part assembly station S of the production line 1 according to the production plan based on the production plan data stored in the production plan data storage unit 20. An order setting unit 40 for setting the order is provided.
A plurality of models of the vehicle body 2 are randomly transported to the production line 1 in response to an order received. At each component assembly station S, for example, which model is transported at what time and on the day is preset. Therefore, it can be determined from the production plan which parts are needed and how much is needed at that time.

  Then, the vehicle body assembly host computer 10 identifies the part shooter 9 corresponding to each passing box 6 based on the order setting result of the order setting unit 40 and the carried-in part data of each passing box 6 transmitted from the carried-in part confirmation part 23. The part shooter assigning part 41 to be assigned and the part shooter carry-in order setting part 42 for setting which position of the corresponding part shooter 9 to carry in based on the order setting result of the order setting part 40 are provided. Yes. The component shooter assigning unit 41 and the component shooter carry-in order setting unit 42 constitute a carry-in instruction unit 26.

  The carry-in instruction unit 26 displays the part number and color number corresponding to the pass box 6 to be carried next on the instruction lamp A provided on the upper part of the parts shelf 8. Correspondingly, the operator reads the barcode of the barcode label L of the corresponding box 6 by the barcode reader 7, and when this is correct, the indicator lamp B of the component shooter 9 to be loaded is lit up. . Therefore, the operator carries the passing box 6 into the component shooter 9 whose indicator lamp B is lit. The indicator lamp A and the indicator lamp B are turned on in order to load the box 6 into the component shooter 9 in the order set by the component shooter assigning unit 41 and the component shooter carry-in sequence setting unit 42. When the button C beside the instruction lamp B is pressed after the passing box 6 is carried into the component shooter 9 of the indicator lamp B that is lit, the part number and color number to be carried in next are displayed on the instruction lamp A. The If the instruction lamp B is not lit when the barcode of the box 6 is read by the barcode reader 7, the part number and the color number displayed by the instruction lamp A are different. It turns out.

  Here, in the case where a plurality of through boxes 6 containing the same parts are successively carried in, when the button C is pressed after the first through box 6 is carried in, the indicator lamp B is temporarily turned off, It lights up again after a certain time. Thus, the operator can reliably carry in each of the through boxes 6 in order when the plurality of through boxes 6 are sequentially carried into the same component shooter 9. The vehicle body assembly host computer 10 is provided with a through box arrangement state confirmation unit 43 for grasping the arrangement state of the through box 6 in the part shooter 9, and each time the through box 6 is carried into each part shooter 9, The arrangement status of the box 6 in the component shooter 9 is updated, and a signal is transmitted from the box arrangement status confirmation unit 43 to the order setting unit 40. Therefore, the parts of the through box 6 that are first carried into the respective part shooters 9 of the parts shelf 8 and are located closest to the carry-out side of the parts shooter 9 become parts that are next carried out toward the production line 1.

  Further, the parts shooter carry-in order setting unit 42 supplies the fractional parts when there is a box 6 in which the fractional parts in which the parts that cannot be continuously supplied to the production line 1 are stored based on the production plan data remain. The pass box 6 containing the parts to be supplied to the production line 1 is set immediately after the pass box 6 in which the fractional parts remain. . That is, when the day is divided into 4 or 8 parts, the parts used for production are stored in the time zone, but all parts stored in the pass box 6 are not necessarily stored at the same time. Since it is not always supplied to the production line, there is a pass box 6 in which fractional parts are generated. If such a pass box 6 is present, the part in the pass box 6 immediately after that cannot be taken out unless the part that has become a fraction in the pass box 6 is used. Immediately after the passing box 6, the passing box 6 containing the parts that can be supplied to the production line 1 is arranged.

  Here, when there is a pass box 6 in which fractional parts in which parts that cannot be continuously supplied to the production line 1 are stored based on the production plan data, the fractional parts are stored by the part shooter allocating unit 41. The box 6 is excluded from the allocation to the parts shooter 9, and a fraction pallet 44 (with casters) is provided separately from the parts shelf 8, and the box 6 with the fractional parts remaining in the fraction pallet 44 is carried in. May be prompted. When the fraction pallet 44 is provided in this manner, the indicator lamp B and the button C are provided on the carry-in side of the fraction pallet 44 and the indicator lamp is provided on the carry-out side. E and button G are provided (see FIGS. 2 and 3).

Accordingly, when the barcode of the barcode label L of the box 6 is read by the barcode reader 7, the carry-in instruction unit 26 of the vehicle body assembly host computer 10 displays the part number and the color number on the indicator lamp A, and carries in the carry-in. The indication lamp B of the component shooter 9 to be lit is displayed.
When the pass box 6 containing the parts displayed on the instruction lamp A is loaded into the parts shooter 9 in which the instruction lamp B is lit, and then the button C is pressed, the part number and color number to be loaded next are indicated. In addition to being displayed on the lamp A, the instruction lamp B of the parts shelf 8 to be loaded is turned on. And the same operation is repeated and the box 6 is carried in. As a result, on the carry-out side of the component shooter 9 of each component shelf 8, the pass box 6 in which the components to be supplied to the production line 1 earliest according to the production order are stored.

(Parts unloading device from the rack center)
As shown in FIGS. 3 and 8, the body assembly host computer 10 sets the order in which parts can be carried out to each part assembly station S of the production line 1 according to the production plan based on the production plan data described above. However, on the basis of the setting result of the order setting unit 40, the number of parts in the passing box 6 on the carry-out side of which part shooter 9 should be instructed via the transfer instruction part 27 A component instruction unit 45 is provided.

  The unloading part instruction unit 45 displays the body number, the part number, and the color number on the instruction lamp D, and lights the instruction lamp E to display the number of parts to be taken out (the number to be conveyed this time). Further, the unloading part instruction unit 45 turns on the instruction lamp F and displays the total number of parts transferred to the transport pallet 14 of the transport carriage 12. Further, the button G is pressed every time one component is taken out. When this button G is pressed, the number of instruction lamps E and instruction lamps F is subtracted and displayed. Therefore, the instruction lamps E and F indicate how many parts should be taken out by the carry-out parts instruction unit 45. Here, when the parts are taken out from the pass box 6 and the empty pass box 6 is taken out, the next pass box 6 moves to the carry-out side. The arrangement state of the box 6 is grasped by the through box arrangement state confirmation unit 43 in consideration of information from the carry-in instruction unit 26. The buttons G and H may be formed integrally with the instruction lamps E and F, respectively.

  In this manner, the necessary parts are transferred from one part shooter 9 to the transport pallet 14 of the transport carriage 12, the number of instruction lamps E becomes zero, and the unloading of the parts is completed. When the unloading part confirmation unit 46 detects, the unloading part instructing unit 45 turns on the indicator lamp E of the part shooter 9 in which the passing box 6 in which the next part to be unloaded is stored is displayed. Finally, the display of the total number of instruction lamps F becomes zero, and the display color of the instruction lamps F changes via the transfer instruction unit 27. Thereafter, when the button H is pressed by the operator, the transfer instruction unit 27 detects this via the carry-out component confirmation unit 46, so the cart supply instruction unit 28 moves the self-propelled vehicle 13 from the standby area ET to the component. Is moved to the stop marker SM laid on the forward path K1 in the vicinity of the parts shelf 8 and the stop portion 13a is stopped and waited. Then, when the operator engages the locking plate 13b of the transport carriage 12 with the locking portion 13a of the self-propelled vehicle 13 waiting, and pushes the start button 13c, the cart supply instructing section 28 detects this push button. Then, an instruction to move the self-propelled transport carriage 11 provided with the transport pallet 14 to the parts assembly station S as the transport destination is output.

  Here, a plurality of component shelves 8 are arranged in the rack center 4, but the carry-out component instruction unit 45 has a component shelf 8 in which the highest priority is given to the delivery of components and the component shelf in which the next priority is given to the delivery of components. In order to discriminate from FIG. 8, the indicator lamp D of the component shelf 8 that gives priority to the removal of the component is turned on, and the instruction lamp D of the component shelf 8 that gives priority to the extraction of the component secondly blinks. it can. Thereby, it can prevent that an operator takes out components only from the components shelf 8 near him. It is possible to turn off the indicator lamp D of the parts shelf 8 where priority is given to taking out the parts after the second.

Accordingly, when the body number, the part number, and the color number are lit and displayed on the instruction lamp D, and the instruction lamp E of the part shooter 9 from which the part is to be taken out is lit, the part of the component shooter 9 in which the instruction lamp E is lit. Is placed on the transport pallet 14 of the transport cart 12. When this operation is being performed, each time a part is transferred, if the button G is pressed, the number of instruction lamps E and the total number of instruction lamps F of the corresponding part shooter 9 will decrease. Then, when the last part is taken out and the number of the indicator lamps E and the total number of the indicator lamps F becomes zero, the display color of the indicator lamps F is changed, so that the operator knows that the unloading is finished visually. Then, when the button H is pressed by the operator, the self-propelled vehicle 13 moves from the standby area ET to the stop marker SM laid on the forward path K1 in the vicinity of the parts shelf 8 that has unloaded the parts. Stop and stand by with 13a protruding. Then, the engaging plate 13b of the transport carriage 12 after the operator has finished the transfer operation and the engaging portion 13a of the waiting self-propelled vehicle 13 are engaged, and the start button 13c is pushed to carry the self-propelled transport. The carriage 11 moves to the parts assembly station S.
When the above-described fraction pallet 44 stores the box 6 in which the fractional parts containing the parts that cannot be continuously supplied to the production line 1 based on the production plan data are stored, this is the fractional pallet 44. Are handled in the same manner as each component shelf 8, and the pass box 6 in which fractional parts are stored can be carried from here. In this case, the instruction lamp E provided on the carry-out side of the fraction pallet 44 is confirmed, the button G is pushed, and the carry-out to the transfer pallet 14 is performed.

  According to the above embodiment, the order setting unit 40 sets the order in which parts can be carried out to each part assembly station S of the production line 1 according to the production plan based on the production plan (order setting process), and the carried-out part confirmation unit 46. While confirming the unloading of the components in the box 6 in which the components are accommodated (unloading component confirmation step), while identifying the arrangement status of the boxes 6 in each component shooter 9 by the through-box arrangement status confirmation unit 43 (Passing box arrangement state confirmation step), based on the order set by the order setting unit 40, the unloading part instruction unit 45 instructs how many parts of the passing box 6 on the unloading side of the part shooter 9 are unloaded ( Unloading parts instruction process), and the unloading box 6 in which parts of different models are stored can be smoothly and accurately delivered to the assembly station S of the production line 1 in order according to the production plan. It can be.

  When the unloading part instruction unit 45 confirms that the uninstructed part has been unloaded from the part shooter 9, the unloading part instructing unit 45 moves the part shooter 9 with the through box 6 containing the parts to be unloaded next. Since the number of parts to be carried out is instructed, the carry-out part instruction unit 45 can grasp the part shooter 9 in which the parts to be carried out next are stored and the number of parts. Therefore, parts can be carried out accurately and easily.

  And since the unloading part instruction | indication part 45 instruct | indicates how many parts are to be carried out as the whole parts shelf 8, the number of parts to be carried out as the whole parts shelf 8 by the unloading parts instruction part 45 Can be grasped. Therefore, it is possible to easily carry out the parts unloading work by facilitating the parts unloading management of the parts shelf 8 as a whole.

Further, when a plurality of component shelves 8 are arranged in the rack center 4, the carry-out component instruction unit 45 has a component shelf 8 in which the highest priority is given to the delivery of components, and the component shelf 8 in which the next priority is given to the delivery of components. Therefore, it is possible to grasp the component shelf 8 that must be immediately unloaded and the component shelf 8 that must be unloaded next. Therefore, although it is an unloading operation in which the unloading order is set, the unloading operation from only the component shelf 8 that is convenient for the operator can be suppressed, and the components can be unloaded from each component shelf 8 without deviation.
The present invention is not limited to the above-described embodiment. For example, the case where a barcode is attached to a box is described as an example. However, the present invention is not limited to such a barcode having data in only one direction. A two-dimensional code having information in vertical and horizontal two dimensions can be applied.

1 is an overall plan view of an embodiment of the present invention. It is the figure seen from the carrying-in side of the parts shelf of embodiment of this invention. It is the figure seen from the carrying-out side of the parts shelf of embodiment of this invention. It is A arrow directional view of FIG. It is a B arrow line view of FIG. It is a top view which shows the self-propelled vehicle storage state of FIG. It is a block diagram which shows the whole system of embodiment of this invention. It is a functional block diagram mainly of a vehicle body assembly host computer according to an embodiment of the present invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Production line 4 Rack center 6 Passing box 8 Parts shelf 9 Parts shooter 20 Production plan data storage part 40 Order setting part 43 Passing box arrangement | positioning condition confirmation part 45 Unloading part instruction | indication part 46 Unloading part confirmation part S Parts assembly station

Claims (4)

Based on the code information, it accepts a box that is placed corresponding to the production line of the product that is produced based on the production plan, accommodates the parts that are brought in from the parts manufacturer and assembled on the production line, and based on the production plan. A component carrying-out device from a rack center having a component shelf that can be carried out in the order of assembly, wherein a plurality of component shooters capable of storing a plurality of the through boxes in the depth direction are provided on the component shelf, and the production plan data is obtained. A production plan data storage unit to be stored, an order setting unit for setting the order in which parts can be carried out to each part assembly station of the production line based on the production plan data, and arrangement of boxes in each part shooter Based on the order setting unit and the box setting status confirmation part for grasping the situation, how many parts of the box on the delivery side of which part shooter should be carried out. And unloading parts instructing unit for instructing either an unloading part confirmation unit for confirming the unloading of the parts in Kayoibako which the component is accommodated, when a plurality of parts shelves are disposed in the rack center, The carry-out component instructing unit instructs a component shelf that gives priority to the carry-out of components and a component shelf that gives priority to the next carry-out of components.   When the unloading part instruction unit confirms that unloading of the part for which the unloading instruction has been issued has been completed, the unloading part instructing unit instructs and unloads the part shooter having a through box in which the part to be unloaded is accommodated. 2. The apparatus for unloading parts from a rack center according to claim 1, wherein the number of parts to be instructed is indicated.   3. The component unloading device from a rack center according to claim 2, wherein the unloading component instruction unit instructs how many components are to be unloaded as the entire component shelf. Based on the code information, it accepts a box that is placed corresponding to the production line of the product that is produced based on the production plan, accommodates the parts that are brought in from the parts manufacturer and assembled on the production line, and based on the production plan. A component carrying-out method from a rack center including a component shelf having a plurality of component shooters that can be carried out in the assembling order, provided with a plurality of component shooters capable of storing a plurality of the through boxes in the depth direction on the component shelf, Based on the production plan, an order setting step for setting the order in which the parts can be carried out to each part assembly station of the production line according to the production plan, and an unloading part confirmation for confirming the unloading of the parts in the pass box containing the parts. Based on the order set by the process, the box arrangement status confirmation step for grasping the arrangement status of the box inside each part shooter, and the order setting step. Comprises a discharge part instruction step of instructing what part to how many out of parts Kayoibako in carry-out side of the chute to have, when a plurality of parts shelves in the rack center is located, the discharge part instruction unit A method for carrying out a part from a rack center, wherein a part shelf that gives the highest priority to the delivery of parts and a part shelf that gives the highest priority to the next part delivery are designated .

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