JP7541297B2 - Cyber-Physical Production System - Google Patents

Description

The present invention relates to a cyber-physical production system.

In a production line that produces workpieces while transporting them in sequence, each of the production machines that make up the production line executes preset processes according to a production plan to produce the workpieces. Patent Document 1 also describes performing a processing simulation using a grinding processing simulation device. By simulating the processing in advance, it is possible to set command values with high accuracy, which makes it possible to improve the productivity of the production line.

Patent Document 2 describes a cyber-physical system (CPS). A CPS, for example, collects various data from the real world (physical space) via a network or the like, and uses data processing technology and the like in the virtual world (cyberspace) to perform analysis, etc., in order to revitalize industry and solve social problems.

JP 2018-153907 A JP 2019-030218 A

In recent years, various production methods have come to be applied in response to the demand for small-lot production of a wide variety of products. For example, in addition to the single-row line production method, which is suitable for mass production, there are also the double-row line production method and the cell production method. The double-row line production method is a method in which multiple production machines are arranged along a workpiece transport line, and there are multiple transport lines. The cell production method is a method in which multiple production machines are not arranged in a line, but are arranged so that workpieces can be transported from a reference position to all of the multiple target production machines. In other words, the double-row line production method and cell production method offer greater freedom in the selection of production processes than the single-row line production method.

For example, when a factory has multiple production machine groups, it is not easy to manage the entire factory as a whole because there is a high degree of freedom in the selection of production processes. Multiple production machine groups include cases where multiple production machine groups of one type of production method are installed, as well as cases where multiple production machine groups of multiple types of production methods are installed.

The present invention aims to provide a cyber-physical production system that can easily and appropriately manage production when there are multiple groups of production machines.

Cyber-physical production system
a plurality of production machine groups arranged in the real world, each of which is composed of a plurality of production machines, and which perform a production process corresponding to a workpiece, and each of which has a plurality of production routes for performing a series of production processes on the workpieces ;
a plurality of individual management computer devices provided corresponding to each of the plurality of production machine groups, which generate an actual production state of the corresponding production machine group as a virtual production state in a virtual world, and select, as individual production management for the corresponding production machine group, a production route to be implemented from among the plurality of production routes based on the virtual production state;
and a host management computer device that determines a new allocation destination of the workpiece from among the plurality of production machines based on a production plan and the individual production management information obtained from each of the plurality of individual management computer devices.
Each of the plurality of production machines includes:
The machine body,
and a control device that controls the machine body based on a control command value.
Each of the plurality of individual management computer devices:
an acquisition unit that acquires the control command value and a detection value detected by a detector constituting the machine body as information on the actual production state of each of the plurality of production machines, and acquires the control command value in synchronization with a control process in the control device and acquires the detection value in synchronization with detection by the detector;
a generating unit that generates, in real time, a current virtual production state and a future virtual production state as the virtual production state of the group of production machines based on the control command value and the detection value acquired by the acquiring unit;
a determination unit which selects, as the individual production management, a production route to be implemented from among a plurality of production routes which can be taken for the workpieces assigned to the corresponding production machine group, based on the current virtual production state and the future virtual production state generated by the generation unit;
a first output unit that outputs the production route selected by the determination unit to a corresponding group of production machines;
and a second output unit that outputs the current virtual production state and the future virtual production state generated by the generation unit to the upper management computer device .

The individual management computer device generates a virtual production state in the virtual world and performs individual production management based on the generated virtual production state. In other words, by utilizing the virtual production state in the virtual world, the individual management computer device can appropriately manage the corresponding group of production machines while predicting the production state of the corresponding group of production machines.

Based on this premise, the host management computer device acquires individual production management information from each of the individual management computer devices. The host management computer device then decides to which production machine group the new workpieces should be assigned based on the acquired individual production management information. In other words, the host management computer device decides to which production machine group the new workpieces should be assigned, taking into account the status of each of the production machines. As a result, it is possible to achieve results according to the desired objective, such as shortening cycle time, reducing power consumption, and reducing tool costs.

FIG. 1 is a configuration diagram of a cyber-physical production system. FIG. 1 is a configuration diagram of a first example of a production machine group. FIG. 1 is a diagram illustrating an example of a production route. FIG. 11 is a diagram showing another example of a production route. FIG. 11 is a configuration diagram of a second example of a production machine group. FIG. 2 is a configuration diagram of an individual management computer device.

(1. Overview of the Cyber-Physical Production System)
The following is an overview of the Cyber Physical Production System (hereafter referred to as "CPPS"). The CPPS in this example is a mechanism for solving problems and creating value for production machines in the real world by accumulating information (actual production status) of production machines that exist in the real world (physical space) in a virtual world (cyberspace) on a computer device and processing the accumulated information in the virtual world.

In particular, the CPPS in this example is intended to use processing in the virtual world to solve problems and create value for a group of production machines in the real world, for example in a case where a group of production machines consisting of multiple production machines is installed in one or multiple production factories. More specifically, in the virtual world, the actual production state of the group of production machines in the real world is generated as a virtual production state, and the group of production machines in the real world is processed or managed. In particular, the CPPS in this example is intended to process or manage the group of production machines in real time by generating a virtual production state in real time and feeding it back to the group of production machines.

Furthermore, the CPPS in this example can target complex events in which multiple production machines that make up a group of production machines are interrelated, and solves problems in the complex events by generating a virtual production state in the group of production machines. In other words, the CPPS does not target simple processes that are completed by a single production machine. However, in addition to the complex events described above, the CPPS may also include simple processes that are completed by a single production machine. An example of a complex event is an event in which the results of a previous process affect the production operations of a subsequent process.

The production machines that make up the production machine group include machines that carry out the production process of workpieces. Production machines include, for example, processing machines, assembly machines, inspection machines, etc. Processing machines include forging machines, casting machines, lathes, machining centers, grinding machines, heat treatment machines, etc. Furthermore, the production machine group includes transfer machines that transport workpieces to each of the multiple production machines. In other words, the transfer machines include transfer robots and transfer conveyors that transport workpieces to processing machines, inspection machines, and assembly machines. Furthermore, the transfer machines have waiting areas for workpieces to wait, and include input devices that input the workpieces into a series of production processes performed by the production machines, etc.

The computer device in the virtual world may be, for example, an edge computer located in a factory, or a cloud computer. An edge computer is a computer installed in a location physically close to the target production machines. Here, the computer device in the virtual world is also capable of acquiring huge amounts of data from the production machines in the real world. However, as described above, the CPPS in this example targets complex events in which multiple production machines are interrelated, and therefore the computer device in the virtual world should only acquire data that affects the event. By limiting the types of data acquired, the network load can be reduced and real-time processing can be achieved.

(2. Overall configuration example of cyber-physical production system 1)
An example of the overall configuration of the CPPS 1 will be described with reference to Fig. 1. As shown in Fig. 1, the CPPS 1 includes a plurality of production machine groups 10A, 10B, 10C, a plurality of individual control computer devices 20A, 20B, 20C, a workpiece allocation device 30, and a host control computer device 40. Although three production machine groups 10A, 10B, 10C are shown in Fig. 1, two or four or more may be used. Since the individual control computer devices 20A, 20B, 20C are provided for each of the production machine groups 10A, 10B, 10C, the number of the individual control computer devices is the same as the number of the production machine groups 10A, 10B, 10C.

Multiple groups of production machines 10A, 10B, 10C are arranged in the real world. The group of production machines 10A is composed of multiple production machines A1-A4. Furthermore, the group of production machines 10A is equipped with a conveying machine A5 that conveys workpieces Wa between the multiple production machines A1-A4. Here, the multiple production machines A1-A4 and the conveying machine A5 form a production area. Workpieces Wa, which are raw materials, are sequentially input into the production area, and workpieces Wb, which are finished products upon completion of production, are removed. Furthermore, in the production area, a series of production processes corresponding to each of the workpieces Wa are carried out.

In other words, the multiple production machines A1-A4 carry out a series of production processes (machining, assembly, inspection, etc.) on the raw material workpiece Wa to produce the finished workpiece Wb. In particular, in this example, the group of production machines 10A has multiple production routes along which a series of production processes are carried out. In other words, the group of production machines 10A can select multiple production routes for one workpiece Wa, and carry out the series of production processes along one production route selected for various reasons.

The group of production machines 10A further includes an input device A6 that inputs the raw material, workpieces Wa, into the production area (the area of the production machines A1-A4 and the conveyor A5). The input device A6 can hold multiple raw workpieces Wa on standby, and inputs the workpieces Wa into the production area one after another. The input device A6 can freely determine the order in which to input multiple workpieces Wa that are ready to be input into the production area.

The production machine groups 10B and 10C have the same configuration as the production machine group 10A. The production machine group 10B is equipped with multiple production machines B1-B4, a conveyor B5, and an input device B6. The production machine group 10C is equipped with multiple production machines C1-C4, a conveyor C5, and an input device C6. Typically, the multiple production machines B1-B4, C1-C4, and conveyors B5, C5 differ in configuration from the production machine group 10A, but are conceptually similar in configuration.

Each of the multiple individual management computer devices 20A, 20B, 20C is provided corresponding to each of the production machine groups 10A, 10B, 10C. The individual management computer device 20A acquires various data from the production machines A1-A4, the conveyor A5, and the input device A6 that make up the production machine group 10A, and generates the actual production state of the production machine group 10A in real time as a virtual production state in the virtual world.

The individual management computer device 20A uses the generated virtual production state to perform individual production management of the group of production machines 10A in real time. In other words, the individual management computer device 20A grasps the actual production state of the group of production machines 10A as a virtual production state in real time, and realizes management and processing according to the state. Individual production management means production management of one group of production machines (e.g., the group of production machines 10A), and for example, grasps the progress of the production process of the workpiece Wa, the operation of the production machines A1-A4, the equipment status of the production machines A1-A4, etc. in that one group of production machines 10A, and takes measures.

The individual management computer device 20A manages and processes the group of production machines 10A so that they autonomously carry out the production process to achieve a predetermined objective. The predetermined objectives include, for example, meeting the target production completion date (delivery date) of the workpiece Wa, reducing power consumption, and reducing tool costs (costs required for cutting tools, grinding wheels, etc.).

The workpiece allocation device 30 allocates new workpieces Wa to one of the multiple production machine groups 10A, 10B, and 10C. For example, the workpiece allocation device 30 stores a large number of workpieces Wa made of raw materials, and allocates and transports the stored workpieces Wa to one of the production machine groups 10A, 10B, and 10C based on an allocation command. Note that in this example, a system is described in which the workpiece allocation device 30 automates the allocation process of the raw workpieces Wa, but an operator may also perform the allocation work based on the allocation command.

The host management computer device 40 determines the allocation destination of the new workpiece Wa from among the multiple production machine groups 10A, 10B, 10C based on the production plan. The host management computer device 40 then outputs an allocation command describing the determined allocation destination to the workpiece allocation device 30 or the worker. The process by which the host management computer device 40 determines the allocation destination is performed, for example, once a day or once half a day. In other words, the process of the host management computer device 40 is not performed in real time. On the other hand, since the individual management computer devices 20A, 20B, 20C perform the process in real time, the process cycle of the host management computer device 40 is sufficiently longer than the process cycle of the individual management computer devices 20A, 20B, 20C.

Here, the upper management computer device 40 determines the allocation destination based on the production plan as well as individual production management information acquired from each of the multiple individual management computer devices 20A, 20B, 20C. In other words, the upper management computer device 40 determines the next allocation destination according to the performance of the multiple production machine groups 10A, 10B, 10C and the equipment status of each production machine. For example, the next allocation destination of the workpiece Wa is determined taking into account information such as when a production machine breaks down or when the cycle time of the workpiece Wa is much longer than expected.

(3. Configuration of production machine groups 10A, 10B, 10C)
(3-1. Applicable production machines)
The groups of production machines 10A, 10B, and 10C can be applied to a single-row line production system, a double-row line production system, and a cell production system (particularly, a dynamic cell production system). The single-row line production system is a system in which a plurality of production machines are arranged along a workpiece transport line, and there is one transport line. The double-row line production system is a system in which a plurality of production machines are arranged along a workpiece transport line, and there are a plurality of transport lines in parallel. The cell production system is a system in which, rather than arranging a plurality of production machines in a single row, they are arranged so that, for example, workpieces can be transported from a reference position to all of the target production machines.

(3-2. First Example of Production Machine Group 10A)
A first example of a group of production machines 10A will be described with reference to Fig. 2. The first example of the group of production machines 10A is a cell production system (dynamic cell production system). The dynamic cell production system is a cell production system in which the sequence of production processes can be changed in real time.

The group of production machines 10A includes single-process machines A1-A3 and a multi-process machine A4 as production machines. The single-process machines A1-A3 are production machines that perform only a single production process. The multi-process machine A4 is a production machine (also called a multifunction machine) that performs multiple production processes.

For example, the group of production machines 10A includes a lathe A1, a cylindrical outer surface grinding machine A2, and a cylindrical inner surface grinding machine A3 as single-process machines, and a multi-task machine A4 as a multi-task machine. The lathe A1 cuts the outer surface, inner surface, axial end surface, flange surface, etc. of the workpiece Wa. The grinding machine A2 grinds the outer surface of the cylindrical workpiece Wa. The grinding machine A3 grinds the inner surface of the cylindrical workpiece Wa. The multi-task machine A4 is capable of turning, grinding the outer surface of the cylinder, and grinding the inner surface of the cylinder. In other words, the multi-task machine A4 can perform each of the production processes of the lathe A1 and the grinding machines A2 and A3.

Thus, turning can be performed by lathe A1 and multi-tasking machine A4, grinding of the outer surface of the cylinder can be performed by grinding machine A2 and multi-tasking machine A4, and grinding of the inner surface of the cylinder can be performed by grinding machine A3 and multi-tasking machine A4. Thus, in this example, the group of production machines 10A includes multiple production machines (e.g., A1, A4) capable of performing the same production process.

Furthermore, the group of production machines 10A is arranged with multiple production machines A1-A4 so that the cell production method can be implemented. For example, the production machines A1-A4 are arranged around a reference position (the position of the conveyor A5). In other words, the reference position is located at the center of the production machines A1-A4. Therefore, the production machines A1-A4 are located within a predetermined distance from the reference position.

Each of the production machines A1-A4 includes a machine body A11-A41, a control device A12-A42, and a detector A13-A43. The control device A12-A42 controls the corresponding machine body A11-A41 based on a control command value. The control command value includes, for example, a position command value for the grinding head (not shown), a rotation command value for the grinding wheel (not shown), and a rotation command value for the workpiece spindle (not shown). In other words, the control command value includes machining conditions such as the machining position, cutting speed, and rotation speed of the rotating body.

Furthermore, the control devices A12-A42 store information about the machine bodies A11-A41, i.e., the type of machine body A11-A41, the production capacity of the production machines A1-A4, the type of tools held by the production machines A1-A4, the status of the tools, etc. The tools here refer to currently installed setup jigs, cutting tools, grinding wheels, etc.

The detectors A13-A43 are sensors that detect the state of the machine main body A11-A41 and the state of the workpiece Wa positioned on the production machine A1-A4. For example, the detectors A13-A43 are sensors that detect the position of a moving body, sensors that detect the moving speed of a moving body, sensors that detect the rotational speed of a rotating body, etc.

The conveyor A5 constitutes the loading position and unloading position of the production area. The conveyor A5 is located at the reference position in the above-mentioned cell production method, i.e., the center of the production machines A1-A4. The conveyor A5 is configured, for example, with a serial type manipulator, and can attach and detach the workpiece Wa at any position in the operable area. The conveyor A5 can transport the workpiece Wa between the loading position on the input device A6 side and the production machines A1-A4, can transport between the production machines A1-A4, and can transport between the production machines A1-A4 and the unloading position.

The conveyor A5 comprises a machine body A51, a control device A52, and a detector A53. The control device A52 controls the machine body A51 based on a control command value. The detector A53 is a sensor that detects the state of the machine body A51 and the state of the workpieces Wa, Wb conveyed by the conveyor A5.

The input device A6 comprises a machine body A61, a control device A62, and a detector A63. The machine body A61 keeps the workpieces Wa allocated by the workpiece allocation device 30 waiting in a state ready for input into the production area. The control device A62 controls the machine body A61 so that the workpieces Wa in a state ready for input are sequentially input into the production area based on an input sequence command. The input sequence command is determined based on information about the workpieces Wa in a state ready for input, a production plan, etc. The detector A63 is a sensor that acquires the state of the machine body A61 and information about the workpieces Wa in a state ready for input in the machine body A61.

(3-3. Production route in the first example of the production machine group 10A)
The production route of the group of production machines 10A in the first example described above will be described with reference to Figures 3 and 4. The group of production machines 10A performs a series of production processes M1, M2, and M3 on a workpiece Wa, as shown in the upper part of Figure 3. For example, the production process M1 is turning, the production process M2 is grinding the outer surface of a cylinder, and the production process M3 is grinding the inner surface of a cylinder. The production sequence (machining sequence) is M1 → M2 → M3.

In this case, as shown in FIG. 3, the group of production machines 10A has seven production routes. Production route 1 is a route in which production process M1 is performed by production machine A1, production process M2 is performed by production machine A2, and production process M3 is performed by production machine A3. This is a production route in which conveyor A5 conveys the workpiece Wa in the order of A1, A2, and A3.

Production route 2 is a route in which production process M3 is performed by production machine A4. It is a production route in which conveyor A5 conveys workpiece Wa in the order of A1, A2, and A4. Production route 3 is a route in which production process M1 is performed by production machine A1, and production processes M2 and M3 are performed by production machine A4. Production route 7 is a route in which all production processes M1, M2, and M3 are performed only by production machine A4. The other production routes are as shown in Figure 3.

The group of production machines 10A performs a series of production processes M4 and M5 on another workpiece Wa, as shown in the upper part of Figure 4. For example, production process M4 is turning, and production process M5 is grinding of the inner surface of a cylinder. The production sequence (machining sequence) is M4 → M5.

In this case, as shown in FIG. 4, the group of production machines 10A has three production routes. Production route 1 is a route in which production process M4 is performed by production machine A1, and production process M5 is performed by production machine A3. It is a production route in which conveyor A5 conveys the workpiece Wa in the order A1, A3. Production route 2 is a route in which production process M4 is performed by production machine A1, and production process M5 is performed by production machine A4. Production route 3 is a route in which production process M4 is performed by production machine A4, and production process M5 is performed by production machine A3.

In this way, when the group of production machines 10A performs a series of production processes M1, M2, and M3 corresponding to the workpiece Wa, it has multiple production routes by selecting one of multiple production machines (e.g., A1, A4) capable of performing the same production process (e.g., M1). In other words, the group of production machines 10A can select from multiple production routes.

(3-4. Second Example of Production Machine Group 10C)
A second example of the group of production machines 10C will be described with reference to Fig. 5. The group of production machines 10C of the second example is configured to be able to implement a double-row line production system. In the group of production machines 10C, multiple production machines C1, C2, and C3 are arranged in a row, and a production machine C4 is arranged in parallel with the row of production machines C1-C3.

In this example, the multiple production machines C1-C4 that make up the production machine group 10C are the same type as the multiple production machines A1-A4 that make up the production machine group 10A in the first example described above. Of course, the two production machines A1-A4 and C1-C4 may be different types.

The production machines C1, C2, C3, and C4 each include a machine body C11, C21, C31, and C41, a control device C12, C22, C32, and C42, and a detector C13, C23, C33, and C43. These are similar to the components of the production machines A1-A4 in the first example, so a description of them will be omitted.

The conveying machine C5 forms a conveying path from the input device C6 to the production machine C1, a conveying path from C1 to C2, a conveying path from C2 to C3, and a conveying path from C3 to the unloading position. Furthermore, the conveying machine C5 forms a conveying path between each of the above conveying paths and the production machine C4. Here, although not shown, the conveying machine C5 is equipped with a machine body, a control device, and a detector, similar to the conveying machine A5 in the first example. The input device C6 is equipped with a machine body C61, a control device C62, and a detector C63. The input device C6 is similar to the input device A6 in the first example, so a description is omitted.

(3-5. Production route in the production machine group 10C of the second example)
The production routes in the group of production machines 10C of the second example are substantially similar to the production routes in the group of production machines 10A of the first example. In other words, the group of production machines 10C of the second example also has multiple production routes as shown in Figures 3 and 4. Therefore, the group of production machines 10C of the second example has multiple production routes arranged in parallel. Note that the number of possible production routes differs depending on the types of the multiple production machines C1-C4 that make up the group of production machines 10C of the second example.

(3-6. Examples of other production machinery)
In the above, lathes and grinding machines are given as examples of production machines, but the dynamic cell production method and double row line production method can be implemented for other processing machines, assembly machines, inspection machines, etc.

(4. Configuration of Individual Management Computer Devices 20A-20C)
The configuration of the individual management computer devices 20A, 20B, and 20C will be described with reference to Fig. 6. Although the following description will be directed to the individual management computer device 20A, the other individual management computer devices 20B and 20C are similar.

The individual management computer device 20A includes a processor (CPU, etc.), a memory device (ROM, RAM, storage, etc.), an interface, etc., and is connected to the group of production machines 10A in the real world via a network. In detail, the individual management computer device 20A is connected to each of the control devices A12, A22, A32, A42, A52, and A62 of the group of production machines 10A. The individual management computer device 20A may be an edge computer or a cloud computer.

As shown in FIG. 6, the individual management computer device 20A includes an acquisition unit 21, a generation unit 22, a decision unit 23, a first output unit 24, and a second output unit 25. The acquisition unit 21 acquires control command values used by the control device A12, etc., in synchronization with the control processing in the control device A12, etc. Furthermore, the acquisition unit 21 acquires information about the machine body A11, etc., stored in the control device A12, etc. Furthermore, the acquisition unit 21 acquires detection values detected by the detector A13, etc., via the control device A12, in synchronization with the detection by the detector A13, etc. Here, the information about the production machine group 10A acquired by the acquisition unit 21 corresponds to information about the actual production status of each of the production machines A1-A4, the conveyor A5, and the input device A6.

For example, in a grinding machine, the acquisition unit 21 acquires information such as spindle specifications (chuck, both centers, etc.), spindle gripping force, grinding wheel power, type of setup jig, maintenance timing, standby power, center distance, processing history, grinding wheel shape, grinding wheel specifications, grinding wheel condition, etc. The acquisition unit 21 also acquires information on workpieces Wa being produced by the production machines A1-A4, and information on workpieces Wa that are in a state of preparation for input by the input device A6. The acquisition unit 21 acquires information such as the progress of the workpieces Wa currently being produced by the production machine group 10A, whether the production machine group 10A is in operation, preparing to operate, stopped due to a malfunction, or undergoing maintenance.

The generation unit 22 generates a virtual production state that represents the actual production state of the group of production machines 10A in a virtual world based on the information acquired by the acquisition unit 21. In particular, the generation unit 22 generates the virtual production state in real time in synchronization with the processing of the control devices A12-A62 of the group of production machines 10A.

Here, the actual production state of the group of production machines 10A is the state of each of the multiple production machines A1-A4, the conveyor A5, and the input device A6 that constitute the group of production machines 10A when the workpiece Wa is being produced in the real world. The virtual production state in the virtual world is a virtual representation of the production state of the group of production machines 10A. In particular, the generation unit 22 generates a virtual production state for events in which the production machines A1-A4 are mutually related. The generation unit 22 generates a current virtual production state and a future virtual production state based on the acquired information. The current virtual production state is information generated by analyzing the information acquired by the acquisition unit 21 and generating the current production states of the production machines A1-A4, the conveyor A5, and the input device A6. The future virtual production state is information generated by analyzing the information acquired by the acquisition unit 21 and estimating the production states of the production machines A1-A4, the conveyor A5, and the input device A6.

Furthermore, the generating unit 22 generates production performance information for the group of production machines 10A based on the information acquired by the acquiring unit 21. For example, the generating unit 22 generates delay information for the production plan, the performance of the cycle time of the assigned workpieces Wa, tool costs resulting from the number of times the grinding wheel is trued, the operating rates of the production machines A1-A4, actual power consumption, etc.

The period during which the generation unit 22 generates the production performance information for the group of production machines 10A (equal to the period during which the virtual production state is generated) should be adjusted to the period during which the upper-level management computer device 40 determines the allocation command. For example, the period during which the production performance information is generated and the period during which the allocation command is determined may be once a day. The generation unit 22 generates the production performance information before the upper-level management computer device 40 determines the allocation command.

The determination unit 23 selects a production route to be implemented from among multiple production routes that can be taken for the target workpiece Wa based on the virtual production state generated by the generation unit 22. In particular, when there are multiple workpieces Wa that are in a state of preparation for being introduced at the introduction device A6, the determination unit 23 selects a production route to be implemented for the workpieces Wa introduced into the production area based on at least one of the delivery date (target production completion date), power consumption, and tool cost for the multiple workpieces Wa in addition to the virtual production state.

Here, the multiple production routes selectable by the determination unit 23 may be stored in advance for each workpiece Wa. In this case, the determination unit 23 performs a process of selecting one production route from the multiple production routes pre-stored for the workpiece Wa. Note that even if the selectable production routes for the workpiece Wa are not pre-stored, a production route can be selected based on information about the workpiece Wa itself, etc.

Furthermore, the determination unit 23 can also determine the order of the workpieces Wa to be input into the production area when there are multiple workpieces Wa in the input device A6 that are ready to be input. In this case, the determination unit 23 determines the order of the workpieces Wa to be input into the production area based on at least one of the delivery date, power consumption, and tool cost for the multiple workpieces Wa that are ready to be input, in addition to the virtual production state. The input order of the workpieces Wa corresponds to the production start order of the workpieces Wa. In other words, the determination unit 23 determines the production start order of the workpieces Wa so as to meet the respective delivery dates of the multiple workpieces Wa, and generates an input order command.

Here, the selection of the production route and the input order taking into account the delivery date may be determined so as to minimize the total delivery date delay of all target workpieces Wa, or so as to minimize the maximum delivery date delay.

The first output unit 24 outputs the production route selected by the decision unit 23 to the control devices A12-A52 of the production machine group 10A. Furthermore, the first output unit 24 outputs the input sequence command determined by the decision unit 23 to the control device A62 of the input device A6. The output processing cycle by the first output unit 24 is, for example, several seconds to several tens of seconds in order to achieve real time.

Therefore, the production machines A1-A5 to which the production route has been output carry out the selected production route for the target workpiece Wa. Furthermore, the input device A6 to which the input sequence command has been output inputs the workpiece Wa into the production area according to the input sequence command.

The second output unit 25 outputs the production performance information generated by the generation unit 22 to the upper management computer device 40. Furthermore, the second output unit 25 outputs the current virtual production state generated by the generation unit 22 to the upper management computer device 40. For example, the second output unit 25 outputs to the upper management computer device 40, as the current virtual production state, whether the production machines A1-A4 are operable or out of order or undergoing maintenance, the type of setup jig currently installed, the number of pieces that can be processed until the next truing of the grinding wheel, etc. Here, unlike the first output unit 24, the output processing cycle of the second output unit 25 does not need to realize real time, and is, as described above, for example, once a day.

(5. Details of the Host Management Computer Device 40)
A detailed description will now be given of the host control computer device 40. The host control computer device 40 determines, based on a production plan, an allocation destination of a new workpiece Wa from among the plurality of production machines 10A, 10B, 10C.

In detail, the upper management computer device 40 determines the allocation destination of the new workpiece Wa from among the multiple production machine groups 10A, 10B, 10C based not only on the production plan but also on the individual production management information acquired from each of the multiple individual management computer devices 20A, 20B, 20C. The individual production management information is information output from the second output section 25 of the individual management computer devices 20A, 20B, 20C.

In other words, the host management computer device 40 determines the allocation destination of the workpiece Wa based on the production plan and taking into consideration the current situation and performance of each of the production machine groups 10A, 10B, and 10C. For example, if the previously determined allocation caused a delivery delay for the production machine group 10B, the host management computer device 40 determines the current allocation destination by estimating the production capacity of the production machine group 10B to be lower than the previous time. Also, if some of the production machines are currently out of order, the host management computer device 40 determines the allocation destination so as to exclude that production machine and prevent delivery delays.

(6. Effects)
As described above, the individual management computer devices 20A, 20B, 20C generate a virtual production state in the virtual world and perform individual production management based on the generated virtual production state. In other words, by using the virtual production state in the virtual world, the individual management computer devices 20A, 20B, 20C can appropriately manage the corresponding groups of production machines 10A, 10B, 10C while predicting the production states of the corresponding groups of production machines 10A, 10B, 10C.

In detail, the individual management computer devices 20A, 20B, 20C generate in the virtual world the individual states of the multiple machines A1-A6, B1-B6, C1-C6 that make up the production machine groups 10A, 10B, 10C. Therefore, the individual management computer devices 20A, 20B, 20C can grasp the state of each of the multiple machines A1-A6, B1-B6, C1-C6 that make up the production machine groups 10A, 10B, 10C.

Then, the individual management computer devices 20A, 20B, and 20C select a production route for the workpiece Wa that is newly input into a series of production processes (production areas) based on the virtual production state. In other words, the individual management computer devices 20A, 20B, and 20C are able to select an appropriate production route taking into account the virtual production state. Therefore, when there are multiple production routes, an appropriate production route can be easily determined.

Then, the selected production route is output to the group of production machines 10A, 10B, 10C, so that the workpiece Wa is processed along the production route selected by the individual management computer devices 20A, 20B, 20C. In other words, the workpiece Wa is processed along an appropriate production route. As a result, it is possible to achieve results according to the desired purpose, such as shortening the cycle time, reducing power consumption, and reducing tool costs.

Then, on the premise that each of the individual management computer devices 20A, 20B, and 20C performs individual production management, the host management computer device 40 acquires individual production management information from each of the individual management computer devices 20A, 20B, and 20C. Then, based on the acquired individual production management information, the host management computer device 40 determines to which of the production machine groups 10A, 10B, and 10C the new workpiece Wa should be assigned.

In other words, the host management computer device 40 determines the allocation destination of the new workpiece Wa by taking into account the status of each of the production machines 10A, 10B, and 10C. As a result, it is possible to achieve results according to the desired objectives, such as shortening the cycle time, reducing power consumption, and reducing tool costs.

1: Cyber Physical Production System (CPPS), 10A, 10B, 10C: Production machines, 20A, 20B, 20C: Individual management computer device, 21: Acquisition unit, 22: Generation unit, 23: Decision unit, 24: First output unit, 25: Second output unit, 30: Workpiece allocation device, 40: Upper management computer device, A1-A4: Production machines, A11-A41: Machine body, A12-A42: Control device, A13-A43: Detector, A5: Conveyor, A51: Machine body, A52: Control device, A53: Detector, A6: Input device, A61: Machine body, A62: Control device, A63: Detector, M1, M2, M3: Production process, Wa, Wb: Workpieces

Claims (5)

a plurality of production machine groups arranged in the real world, each of which is composed of a plurality of production machines, and which perform a production process corresponding to a workpiece, and each of which has a plurality of production routes for performing a series of production processes on the workpieces ;
a plurality of individual management computer devices provided corresponding to each of the plurality of production machine groups, which generate an actual production state of the corresponding production machine group as a virtual production state in a virtual world, and select, as individual production management for the corresponding production machine group, a production route to be implemented from among the plurality of production routes based on the virtual production state;
a host management computer device that determines a new allocation destination of the workpiece from among the plurality of production machines based on a production plan and information on the individual production management obtained from each of the plurality of individual management computer devices ,
Each of the plurality of production machines includes:
The machine body,
a control device that controls the machine body based on a control command value,
Each of the plurality of individual management computer devices:
an acquisition unit that acquires the control command value and a detection value detected by a detector constituting the machine body as information on the actual production state of each of the plurality of production machines, and acquires the control command value in synchronization with a control process in the control device and acquires the detection value in synchronization with detection by the detector;
a generating unit that generates, in real time, a current virtual production state and a future virtual production state as the virtual production state of the group of production machines based on the control command value and the detection value acquired by the acquiring unit;
a determination unit which selects, as the individual production management, a production route to be implemented from among a plurality of production routes which can be taken for the workpieces assigned to the corresponding production machine group, based on the current virtual production state and the future virtual production state generated by the generation unit;
a first output unit that outputs the production route selected by the determination unit to a corresponding group of production machines;
a second output unit that outputs the current virtual production state and the future virtual production state generated by the generation unit to the upper management computer device . 2. The cyber-physical production system according to claim 1, wherein the upper management computer device determines a new allocation destination of the workpiece from among the plurality of production machines based on the production plan, and the current virtual production state and the future virtual production state output from the second output section of each of the plurality of individual management computer devices. Each of the plurality of individual management computer devices:
generating the virtual production state of the group of production machines based on the actual production state of each of the plurality of production machines;
3. The cyber-physical production system according to claim 1 , wherein the individual production management is performed for the workpieces assigned to the group of production machines based on the generated virtual production state. 4. The cyber-physical production system according to claim 3 , wherein a period during which the host management computer device determines the allocation destination of the workpieces is longer than a period during which the individual management computer device generates the virtual production state. The cyber-physical production system of any one of claims 1 to 4 , wherein each of the plurality of individual management computer devices includes at least one of delay information for a production plan and actual cycle time of the assigned workpieces as the individual production management information.

Images