JP7752356B2 - Trouble analysis support method, trouble analysis support device, and program - Google Patents

Description

This disclosure relates to a trouble analysis support method, a trouble analysis support device, and a program.

When a problem occurs with production equipment such as component mounting equipment, the production data used to operate the production equipment, various settings, and other operating conditions are used to recreate the problem, and then verification and countermeasures are considered (see Patent Document 1).

JP 2016-018830 A

However, while the technology in Patent Document 1 focuses on reproducing the flow of commands issued to production equipment up until the time a problem occurs, simply reproducing the flow of commands may not faithfully reproduce the problem state of the production equipment. It is also desirable to be able to easily reproduce the problem state.

This disclosure provides a trouble analysis support method, a trouble analysis support device, and a program that can more faithfully and easily reproduce trouble conditions in production equipment.

A trouble analysis support method according to one aspect of the present disclosure supports trouble analysis of production equipment consisting of one or more units by simulating the operation of the production equipment. The method includes: a command response acquisition step of acquiring, from a first operation log including an operation history at the time a trouble occurred in the production equipment, a first command response, which is a response from the one or more units to a first command issued to the one or more units; and a simulation step of simulating the operation of the production equipment based on the acquired first command response. The simulation step includes a command issuing step of issuing a second command corresponding to the first command to one or more virtual units in the simulation corresponding to the one or more units; a command execution step of executing the second command in the one or more virtual units; and a command response issuing step of issuing a second command response, which is a response from the one or more virtual units to the second command. In the command response issuing step, the acquired first command response is issued as the second command response.

A trouble analysis support device according to one aspect of the present disclosure supports the analysis of trouble in production equipment consisting of one or more units by simulating the operation of the production equipment. The device includes an acquisition unit that acquires, from a first operation log containing the operation history of the production equipment when a trouble occurred, a first command response, which is the response of the one or more units to a first command issued to the one or more units, and a simulation processing unit that simulates the operation of the production equipment based on the acquired first command response. The simulation processing unit issues a second command corresponding to the first command to one or more virtual units in a simulation corresponding to the one or more units, executes the second command in the one or more virtual units, and issues a second command response, which is the response of the one or more virtual units to the second command. When issuing the second command response, the acquired first command response is issued as the second command response.

A program according to one aspect of the present disclosure is a program for causing a computer to execute the above-described trouble analysis support method.

One aspect of the present disclosure makes it possible to realize a trouble analysis support method that can more faithfully and easily reproduce trouble conditions in production equipment.

FIG. 1 is a diagram showing the overall configuration of a trouble analysis support system according to an embodiment. FIG. 2 is a block diagram showing the functional configuration of an actual manufacturing system according to an embodiment. FIG. 3 is a diagram illustrating an example of a first operation log according to the embodiment. FIG. 4 is a block diagram showing the functional configuration of a manufacturing system on a software simulator in the analysis support device according to the embodiment. FIG. 5 is a sequence diagram illustrating the operation of the analysis support device according to the embodiment. FIG. 6 is a flowchart showing the operation of each unit of the analysis support device according to the embodiment.

(Background to this application)
Patent Document 1 discloses a component mounting device (mounter) that has a production mode and an operation reproduction mode, and that reproduces the operation at the time of the trouble in the operation reproduction mode by using the operating conditions at the time of the trouble that were saved in the production mode. In other words, Patent Document 1 discloses that the trouble state is reproduced using the component mounting device itself in which the trouble occurred. Patent Document 1 also discloses that commands to be used when reproducing the trouble state in the operation reproduction mode are generated based on the operating conditions at the time of the trouble in the production mode, and the operation at the time of the trouble is reproduced using the generated commands.

However, just because the same component mounting device is used to reproduce the flow of command issuance when a problem occurs does not mean that the command responses of each unit in response to the issued commands can be completely reproduced.

Furthermore, with the technology of Patent Document 1, the problem is reproduced using the component mounting device on which the problem occurred, so production cannot be carried out while the problem is being reproduced using that component mounting device. In other words, with the technology of Patent Document 1, it is not possible to reproduce the problem without affecting production.

In this disclosure, we have conducted extensive research into a trouble analysis support method, trouble analysis support device, and program that can more faithfully and easily reproduce trouble conditions in production equipment, and have devised the trouble analysis support method, trouble analysis support device, and program described below.

A trouble analysis support method according to one aspect of the present disclosure supports trouble analysis of production equipment consisting of one or more units by simulating the operation of the production equipment. The method includes: a command response acquisition step of acquiring, from a first operation log including an operation history at the time a trouble occurred in the production equipment, a first command response, which is a response from the one or more units to a first command issued to the one or more units; and a simulation step of simulating the operation of the production equipment based on the acquired first command response. The simulation step includes a command issuing step of issuing a second command corresponding to the first command to one or more virtual units in the simulation corresponding to the one or more units; a command execution step of executing the second command in the one or more virtual units; and a command response issuing step of issuing a second command response, which is a response from the one or more virtual units to the second command. In the command response issuing step, the acquired first command response is issued as the second command response.

By using the first operation log, which has not been used in the past, the behavior of each virtual unit in the simulation can be made closer to the behavior of each unit in reality. In other words, the trouble state of production equipment can be reproduced more faithfully in the simulation. This contributes to efficient cause analysis, data analysis, and response considerations when a trouble occurs in production equipment, for example. Furthermore, because the production equipment in which the trouble occurred is not used to reproduce the trouble state, the trouble state can be reproduced without affecting production. Therefore, a trouble analysis support method can be realized that can reproduce the trouble state of production equipment more faithfully and easily.

Furthermore, for example, the method may further include an operation log generation step of generating a second operation log including the second command response for each of the one or more virtual units, and a first determination step of determining whether the first operation log and the second operation log match.

This allows a determination to be made as to whether the first operation log and the second operation log match, thereby informing the user whether the behavior of each real unit is being perfectly reproduced on each virtual unit.

Furthermore, for example, if it is determined in the first determination step that the first operation log and the second operation log do not match, the first operation log may be edited, and the simulation step may be executed again based on the edited first operation log.

This allows the degree of agreement between the first and second operation logs to be increased if they do not match, thereby more faithfully reproducing the trouble state of the production equipment in the simulation.

Also, for example, the one or more virtual units may include a first virtual unit and a second virtual unit, the first operation log may include a first command response corresponding to only one of the first virtual unit and the second virtual unit, and the edited first operation log may include an additionally obtained first command response corresponding to the other virtual unit of the first virtual unit and the second virtual unit.

This allows the first command responses issued by the real units to be added to the first operation log, making it possible to more accurately reproduce the behavior of each real unit on each virtual unit.

Also, for example, the one or more virtual units may include a first virtual unit and a second virtual unit, the first operation log may include a first command response of only one of the first virtual unit and the second virtual unit, and the edited first operation log may include a dummy value of the first command response of the other virtual unit of the first virtual unit and the second virtual unit.

This allows a dummy value to be added to the first operation log as the first command response for units that have not received a first command response issued by a real unit, making it easy to reproduce the behavior of each real unit on each virtual unit.

Furthermore, for example, the method may further include a second determination step of determining the type of the acquired second command, and in the command response issuing step, a first command response corresponding to the unit is extracted from the first operation log according to the determined type of the second command, and the extracted first command response is issued as the second command response.

As a result, each virtual unit automatically obtains the first command response corresponding to that virtual unit from the first operation log, allowing the process from obtaining the first command response to issuing the second command response to be performed automatically.

Furthermore, for example, the first command and the second command may be commands generated based on production data related to production when a problem occurs in the production equipment and setting conditions of the one or more units.

As a result, the first command and the second command become the same command, making it possible to more faithfully reproduce the trouble state of the production equipment.

A trouble analysis support device according to one aspect of the present disclosure supports trouble analysis of production equipment consisting of one or more units by simulating the operation of the production equipment. The trouble analysis support device includes an acquisition unit that acquires, from a first operation log containing operation history at the time a trouble occurred in the production equipment, a first command response, which is the response of the one or more units to a first command issued to the one or more units; and a simulation processing unit that simulates the operation of the production equipment based on the acquired first command response. The simulation processing unit issues a second command corresponding to the first command to one or more virtual units in a simulation corresponding to the one or more units, executes the second command in the one or more virtual units, and issues a second command response, which is the response of the one or more virtual units to the second command. In issuing the second command response, the acquired first command response is issued as the second command response. A program according to one aspect of the present disclosure is a program for causing a computer to execute the above-described trouble analysis support method.

This achieves the same effect as the above-mentioned troubleshooting support method.

The following describes the embodiments in detail, with reference to the drawings.

The embodiments described below are all comprehensive or specific examples. The numerical values, shapes, components, component placement and connection configurations, steps, and step order shown in the following embodiments are merely examples and are not intended to limit the present disclosure. Furthermore, among the components in the following embodiments, components that are not recited in independent claims are described as optional components.

Furthermore, each figure is a schematic diagram and is not necessarily an exact illustration. Therefore, for example, the scales of the figures do not necessarily match. Furthermore, in each figure, substantially identical components are assigned the same reference numerals, and redundant explanations are omitted or simplified.

In addition, in this specification, the terms "unit" and "device" are not limited to physical components that are mechanically realized by hardware, but also include components in which at least some of the functions of the components are realized by software such as a program.

In addition, in this specification, terms indicating relationships between elements, such as "match," as well as numerical values and numerical ranges, are not expressions that express only the strict meaning, but also expressions that include a substantially equivalent range, for example, a difference of a few percent (e.g., about 10%).

(Embodiment)
A trouble analysis support system including an analysis support device according to this embodiment will be described below with reference to FIGS.

[1. Configuration of the trouble analysis support system]
First, the configuration of a trouble analysis support system according to this embodiment will be described with reference to Figures 1 to 4. Figure 1 is a diagram showing the overall configuration of a trouble analysis support system 1 according to this embodiment.

As shown in FIG. 1, the trouble analysis support system 1 includes a manufacturing system 10, an analysis support device 100, and a display device 200. The trouble analysis support system 1 is an information processing system for reproducing troubles that occur in the manufacturing system 10 through simulation using the analysis support device 100. The manufacturing system 10 (e.g., the control device 20) and the analysis support device 100 are connected to each other so that they can communicate with each other. The communication method may be wired communication or wireless communication.

The manufacturing system 10 is a real manufacturing system located in a factory or the like, and includes a control device 20 and one or more component mounting devices 30. The one or more component mounting devices 30 form a manufacturing line.

The control device 20 manages production in the manufacturing system 10. The control device 20 controls one or more component mounting devices 30 on the production line, for example, based on production data and setting conditions. The control device 20 generates commands to control each unit based on production data input from outside and setting conditions for each unit that makes up the component mounting device 30, and issues the generated commands to each unit. In other words, the control device 20 outputs commands to each unit. The control device 20 also obtains command responses, which are responses to the commands, from each unit. The commands issued by the control device 20 to each unit of the component mounting device 30 are an example of first commands.

Production data is data related to production, and includes information about the boards to be produced and the components to be mounted, production quantities, production time, etc.

The setting conditions are the setting conditions for each unit of the component mounting device 30, and include information such as the conditions for the components of each unit (e.g., the conditions for the suction nozzle), the component mounting position, etc.

A command is an instruction regarding the operation or processing content for controlling each unit, and may, for example, cause each unit to perform a specified operation, obtain a measurement value using a sensor, or output a determination result as to whether the measurement value is normal. If the unit is a component mounting head unit 32, the specified operation may be, for example, a pickup operation, a correction operation, a mounting operation, etc., and the measurement value may be a flow rate value, a position correction value, etc. The determination result may also be whether the flow rate value or the mounting position is normal.

The command response is each unit's response to the command, and if the unit is a component mounting head unit 32, it includes the flow rate value or status information such as a pickup error or mounting error.

A problem occurs when a unit does not operate normally in response to a command issued by the control device 20, and, for example, when production cannot be carried out as intended. If the unit is a component mounting head unit 32, the problem may be, for example, a flow rate error or a mounting error. The problem may also be an error that causes the component mounting device 30 to stop operating.

In addition, information summarizing the command responses of each unit will also be recorded in the operation log.

The control device 20 outputs production data, setting conditions, and operation logs before and after the occurrence of the problem to the analysis support device 100. The production data, setting conditions, and operation logs are information used by the analysis support device 100 to reproduce the operation of the component mounting device 30. In this embodiment, the control device 20 outputs an operation log (first operation log 50, described below) to the analysis support device 100 as information used to reproduce the operation of the component mounting device 30.

The component mounting device 30 is an example of production equipment that makes up a production line, and is a mounting device that mounts components onto objects (workpieces) such as circuit boards. The configuration of the component mounting device 30 will be described later using Figure 2.

The components are electronic components, such as, but not limited to, resistors and capacitors. The target object is not limited to a substrate, but may be any workpiece that can be subjected to the specified processing.

The analysis support device 100 reproduces the operation of the component mounting device 30 in a simulation based on production data, setting conditions, and operation logs. The analysis support device 100 simulates the operation (processing) of the component mounting device 30. In this embodiment, the analysis support device 100 reproduces in a simulation the operation of the component mounting device 30 when a problem occurs in the component mounting device 30.

The analysis support device 100 is implemented using a personal computer or the like, but may also be implemented using a mobile device such as a tablet terminal.

The display device 200 displays images output from the analysis support device 100. The display device 200 displays information related to the operation of the component mounting device 30 reproduced in the simulation. The display device 200 may be realized, for example, by a liquid crystal display or the like, but is not limited to this.

The trouble analysis support system 1 may also include a reception device (not shown) that receives input from the user. The trouble analysis support system 1 may receive instructions for the analysis support device 100 via the reception device. The reception device may include a keyboard, buttons, a touch panel, etc., or may include a microphone for receiving audio.

In addition, at least one of the analysis support device 100 and the display device 200 may be installed outside the factory where the manufacturing system 10 is located.

The configuration of the manufacturing system 10 will now be described further with reference to Figures 2 and 3. Figure 2 is a block diagram showing the functional configuration of an actual manufacturing system 10 according to this embodiment. In Figure 2, solid arrows indicate commands issued by the control device 20 to each unit of the component mounting device 30, and dashed arrows indicate command responses issued from each unit to the control device 20.

As shown in FIG. 2, the manufacturing system 10 includes a control device 20, a component mounting device 30, and a memory unit 40. In FIG. 2, for convenience, the control device 20 controls one component mounting device 30, but there may be multiple component mounting devices 30. There is no particular limit to the number of component mounting devices 30 controlled by the control device 20.

The control device 20 issues commands to each unit of the component mounting device 30 based on the production data D1 and setting conditions D2 acquired from the outside. For example, when the control device 20 causes the component mounting head unit 32 to pick up a component, it issues a flow rate value check command to the component mounting head unit 32.

The control device 20 also acquires command responses from each unit in response to the issued command. For example, the control device 20 acquires a command response including a flow rate value or a determination result of the flow rate value from the component mounting head unit 32 as a response to a flow rate value check command. The control device 20 may store the command responses acquired from each unit in the memory unit 40 as a first operation log 50. The first operation log 50 is information summarizing the command responses of each unit of the component mounting device 30, and is a log that records the operation history of the component mounting device 30. The first operation log 50 includes information summarizing the command responses of each unit of the component mounting device 30 when a problem occurs in the component mounting device 30.

The component mounting device 30 is composed of multiple units. In this embodiment, the component mounting device 30 includes a component supply unit 31, a component mounting head unit 32, a component recognition unit 33, an axis control unit 34, and a board transport control unit 35. Each unit includes a processing unit (software processing unit) that processes commands such as a CPU, and a physical configuration (hardware) that operates based on the commands.

The component supply unit 31 has one or more feeders arranged side by side, and supplies components to a pick-up position by the component mounting head unit 32. The feeders are, for example, tape feeders, but may also be, for example, bulk feeders. A command to the component supply unit 31 is to supply a component to the pick-up position, and the command response is, but is not limited to, information identifying the feeder that supplied the component, or information indicating whether the component supply was completed successfully.

The component mounting head unit 32 mounts (mounts) components placed at the pick-up position of the component supply unit 31 onto the board. The component mounting head unit 32 is configured to include a mounting head (head) equipped with component suction nozzles (nozzles) that can pick up components from a feeder and move up and down individually. The head may be equipped with, for example, multiple nozzles. The component mounting head unit 32 may also have a sensor such as a flow sensor that measures the flow rate of air flowing through the nozzle. Commands sent to the component mounting head unit 32 include picking up a component from the component supply unit 31 (component pickup command), mounting a component onto the board, checking the flow rate value, etc., and command responses include, but are not limited to, information indicating whether component pickup or component mounting was completed successfully, the measured flow rate value, etc.

The component recognition unit 33 includes an imaging device such as a camera, and recognizes components by capturing an image of the component. When the mounting head picks up a component from a feeder arranged in the component supply unit 31 and moves above the camera, the component recognition unit 33 captures an image of the component held by the mounting head. The component recognition unit 33 identifies and detects the position of the component by processing the captured image using image recognition in a processing unit (not shown). The component recognition unit 33 may function, for example, as a sensor to determine whether a nozzle has picked up a component and to detect the amount of deviation in the pickup position of the picked-up component. A command to the component recognition unit 33 is to recognize the component, and the command response is, but is not limited to, the component recognition result (e.g., positional deviation), etc.

The axis control unit 34 controls the drive of the servo motor to move the component mounting head unit 32. This controls the position of the nozzle mounted on the component mounting head unit 32. The command sent to the axis control unit 34 is to move the nozzle to a specified position, and the command response includes, but is not limited to, information indicating whether the nozzle movement was completed successfully, the block number supporting the nozzle, etc.

The board transport control unit 35 transports boards carried in from the upstream side in a direction along the manufacturing system 10, and positions and holds them on a mounting stage set up for component mounting work. The board transport control unit 35 is configured to include, for example, one or more transport lanes. Commands sent to the board transport control unit 35 include transporting a board, and command responses include, but are not limited to, information indicating whether the board transport was completed successfully or any positional misalignment.

In addition, each unit is equipped with various sensors that detect the operation of that unit. Each unit is equipped with various sensors that can detect problems with that unit.

The number of units that the component mounting device 30 has is not particularly limited, as long as it is one or more. The configuration of the component mounting device 30 is not limited to the above, and can be determined appropriately depending on the type, shape, and processing method of the object and component.

The memory unit 40 is a storage device that stores various information for manufacturing in the manufacturing system 10, as well as measurement values measured during manufacturing. In this embodiment, the memory unit 40 stores a first operation log 50. The first operation log 50 contains the same information as the command responses issued by each unit. The first operation log 50 may be, for example, time-series data of the command responses of each unit.

Furthermore, the memory unit 40 may store, for example, commands issued by the control device 20 to each unit, or may store production data D1 and setting conditions D2.

Figure 3 is a diagram showing an example of a first operation log 50 according to this embodiment. The first operation log 50 shown in Figure 3 is, for example, a command response based on common production data D1 and setting conditions D2.

As shown in FIG. 3, the first operation log 50 includes axis control unit data values, component supply unit data values, component mounting head unit data values, status information data values, and component recognition unit data values. The axis control unit data values are values based on the command response of the axis control unit 34, and in the example of FIG. 3, include the block number, coordinate ID number, turn number, mounting order, and pickup order. The component supply unit data values are values based on the command response of the component supply unit 31, and in the example of FIG. 3, include the physical feeder address number and feeder serial number.

The component placement head unit data value and the status information data value are values based on the command response of the component placement head unit 32. In the example of Figure 3, the component placement head unit data value includes the nozzle holder address number and the nozzle serial number, and the status information data value includes the placement status and the flow rate value. The placement status indicates whether a placement error has occurred, and the flow rate value indicates the measurement value of the flow rate sensor. The component recognition unit data value is a value based on the command response of the component recognition unit 33. In the example of Figure 3, the data value includes the recognition correction amounts X1, Y1, and A, the pickup correction amounts X2 and Y2, and the pickup learning amounts X3 and Y3. The recognition correction amounts X1, Y1, and A respectively indicate the positional deviation of the component from the reference at the component supply position (the correction amount of the pickup position when picked up by the nozzle), and indicate the deviation of the component in the X-axis direction, Y-axis direction, and rotational direction. The pickup correction amounts X2 and Y2 respectively indicate the deviation of the pickup position from the reference when the nozzle picks up a component (the correction amount of the nozzle position relative to the component mounting position), and indicate the nozzle's positional deviation in the X-axis and Y-axis directions.

The first operation log 50 may be, for example, time-series data for a predetermined period of time. The predetermined period is a period that includes the time when a problem occurred in the component mounting device 30, and may be a period before or after that time, or a period in the past that includes that time. For example, using flow rate values as an example, the first operation log 50 may include changes in flow rate values over time. The first operation log 50 can also be said to include detailed information on behavior during command responses (e.g., changes in flow rate values over time). Behavior refers to the state or change in state of each unit based on actual measured values; for example, if the unit is a component mounting head unit 32, it may be the flow rate value or changes in flow rate values over time, but is not limited to this.

In the example of Figure 3, the first operation log 50 does not include values based on the command response of the board transport control unit 35, but this is not limited to this and values based on the command response of the board transport control unit 35 may also be included.

Note that, although FIG. 2 illustrates an example in which the first operation log 50 is generated by the control device 20 and stored in the memory unit 40, this is not limiting and, for example, the first operation log 50 may be obtained directly from each unit. The first operation log 50 may also be created based on command responses obtained directly from each unit without going through the control device 20.

Next, the configuration of the analysis support device 100 will be described with reference to Figure 4. Figure 4 is a block diagram showing the functional configuration of the manufacturing system 10 on the software simulator in the analysis support device 100 according to this embodiment.

As shown in FIG. 4, the analysis support device 100 includes a control unit 120 and a component mounting device 130. The control unit 120 and the component mounting device 130 represent the functional configuration of the software simulator.

The control unit 120 performs processing on the simulator equivalent to that of the control unit 20 of the manufacturing system 10. Specifically, the control unit 120 issues commands to each unit of the component mounting device 130 based on production data D1 and setting conditions D2 acquired from outside. The control unit 120 is configured to issue the same commands as the control unit 20 when the same production data D1 and setting conditions D2 as those of the control unit 20 are input. The control unit 120 may be configured, for example, to issue the same commands as the control unit 20 to each unit in the same order and timing as the control unit 20. The production data D1 and setting conditions D2 input to the control unit 120 are the production data D1 and setting conditions D2 actually used to operate the component mounting device 30; for example, they may be the same as the production data D1 and setting conditions D2 when a problem occurred in the manufacturing system 10, but are not limited to this.

The component mounting device 130 is a simulation model corresponding to the component mounting device 30 for simulating the operation of the component mounting device 30. The component mounting device 130 includes one or more units (virtual units, which are modeled units). In the example of FIG. 4, the component mounting device 130 includes a component supply unit 131, a component mounting head unit 132, a component recognition unit 133, an axis control unit 134, and a board transport control unit 135. One of the component supply unit 131, the component mounting head unit 132, the component recognition unit 133, the axis control unit 134, and the board transport control unit 135 is an example of a first virtual unit, and the other unit is an example of a second virtual unit.

The component supply unit 131 is a modeled unit corresponding to the component supply unit 31 and has functions equivalent to the software processing unit of the component supply unit 31. The component mounting head unit 132 is a modeled unit corresponding to the component mounting head unit 32 and has functions equivalent to the software processing unit of the component mounting head unit 32. The component recognition unit 133 is a modeled unit corresponding to the component recognition unit 33 and has functions equivalent to the software processing unit of the component recognition unit 33. The axis control unit 134 is a modeled unit corresponding to the axis control unit 34 and has functions equivalent to the software processing unit of the axis control unit 34. The board transport control unit 135 is a modeled unit corresponding to the board transport control unit 35 and has functions equivalent to the software processing unit of the board transport control unit 35. A first operation log 50 is input to the component mounting device 130. The first operation log 50 includes command responses corresponding to the production data D1 and setting conditions D2 input to the control unit 120.

Conventionally, each unit in a simulation is configured to operate in a steady state. For example, when a command is input, each unit issues a command response indicating normal operation. For example, even if a command based on production data D1 and setting conditions D2 is input when a problem occurs in component mounting device 30, each unit will issue a command response indicating normal operation. In this way, conventionally, it is possible to match the commands issued by control unit 120 with the commands issued by control device 20, but it is not possible to match the command responses issued by each unit. In other words, conventionally, it is not possible to reproduce the behavior of each unit in a simulation. For example, the pickup state and mounting state during an error cannot be reproduced in a simulation.

However, from the perspective of easily analyzing the causes of problems that occur in the component mounting device 30, it is desirable to match the behavior of each unit or sensor in the simulation with the behavior of each unit or sensor in the actual component mounting device 30.

In this embodiment, when a command is input to each unit in the simulation, it extracts a command response corresponding to the command from the first operation log 50 and issues the extracted command response to the control unit 120. When a command from the control unit 120 is input to each unit, it replaces the command response with a command response indicating normality and issues the command response extracted from the first operation log 50 to the control unit 120. This makes it possible to match the behavior of each unit in the simulation with the behavior of each unit in the actual component mounting apparatus 30. For example, it is possible to match the behavior of each unit or sensor in the actual component mounting apparatus 30 when a problem occurs with the behavior of each unit or sensor in the simulation. For example, using flow rate values as an example, it is possible to match the change over time in the flow rate value, which is the command response of the component mounting head unit 132 in the simulation, with the change over time in the flow rate value, which is the command response of the actual component mounting head unit 32, until the problem occurs.

Note that the match here is not limited to a perfect match, and at least some of the behavior may differ. For example, because the first operation log 50 does not include the command response of the board transport control unit 35, the command response of the board transport control unit 135 in the simulation may not match the command response of the board transport control unit 35. Furthermore, there may be units (not shown) other than those shown in Figures 2 and 4, and the command response in the simulation may not match the command response of the actual component mounting device 30 due to the influence of these units.

In addition, information summarizing the command responses issued from each unit (virtual unit) of the component mounting device 130 is referred to as the second operation log 150. The second operation log 150 is a log equivalent to the first operation log 50 acquired by the manufacturing system 10 in the trouble analysis support system 1, and is a log that records the operation history of the component mounting device 130. The second operation log 150 includes information summarizing the command responses of each unit (each virtual unit) of the component mounting device 130 when a problem occurs in the component mounting device 130. From the perspective of easily analyzing the cause of the problem, it is preferable that the second operation log 150 match the first operation log 50.

2. Operation of the analysis support device
Next, the operation of the analysis support device 100 configured as described above will be described with reference to Figures 5 and 6. Figure 5 is a sequence diagram showing the operation of the analysis support device 100 according to this embodiment. Steps S13 to S17 shown in Figure 5 are an example of a simulation step that simulates the operation of the component mounting device 30 based on the command response (an example of a first command response) acquired from the first operation log 50.

As shown in FIG. 5, when a problem occurs in the actual component mounting device 30, the control device 20 outputs a first operation log 50 to the component mounting device 130, and the component mounting device 130 acquires the first operation log 50 (S11).

Next, the component mounting device 130 extracts a command response from the first operation log 50 (S12). Each unit of the component mounting device 130 extracts a command response corresponding to the command issued to that unit from the first operation log 50. Each unit of the component mounting device 130 also extracts a command response corresponding to that unit from the first operation log 50. It can also be said that each unit of the component mounting device 130 obtains a command response (an example of a second command response) from the first operation log 50, which is the response of each unit to the command issued to that unit (an example of a second command). Step S12 is an example of a command response acquisition step.

Next, the control unit 120 generates commands to control each unit (each virtual unit) of the component mounting device 130 based on the production data D1 and setting conditions D2 when a problem occurs in the component mounting device 30 (S13), and the generated commands are issued from each unit (each virtual unit). In other words, in step S13, a second command corresponding to the first command is issued to each unit (each virtual unit) in the simulation. The first command and the second command may be commands generated based on the production data D1 and setting conditions D2 when a problem occurs in the component mounting device 30. The first command and the second command may be the same command. Step S13 is an example of a command issuing step.

Next, the control unit 120 issues the generated command to each unit, and each unit receives the issued command (S14).

Next, the component mounting device 130 executes the acquired command (S15). Specifically, each unit of the component mounting device 130 executes a command appropriate to that unit. Each unit of the component mounting device 130, for example, executes a process that simulates hardware operation. Step S15 is an example of a command execution step.

Next, the component mounting device 130 sets the command response extracted in step S12 as the command response to the command executed in step S15 (S16). It can also be said that the component mounting device 130 sets the command response extracted in step S12 as the second command response. This allows the component mounting device 130 to reproduce the problem that occurred in the component mounting device 130.

Next, the component mounting device 130 issues a command response, and the control unit 120 acquires the command response (S17). In step S17, it can also be said that a first command response is issued as a second command response, which is the response of each unit (each virtual unit) to the second command. Step S17 is an example of a command response issuing step.

Next, the control unit 120 generates a second operation log 150 (S18). The control unit 120 generates the second operation log 150 including the command responses issued by each unit to the control unit 120 in step S17. Step S18 is an example of an operation log generation step.

Next, the control unit 120 outputs the second operation log 150 to the component mounting device 130, and the component mounting device 130 acquires the second operation log 150 (S19).

Next, the component mounting device 130 determines whether the first operation log 50 and the second operation log 150 match (S20). Step S20 is an example of a first determination step.

If the first operation log 50 and the second operation log 150 match (Yes in S20), the component mounting device 130 continues analyzing the cause of the problem. If the first operation log 50 and the second operation log 150 do not match (No in S20), the component mounting device 130 edits the first operation log 50 (S21), returns to step S12, and continues processing using the edited first operation log 50. In step S21, the component mounting device 130 may add to the first operation log 50 a first command response corresponding to the other virtual unit of the first virtual unit and the second virtual unit, which first command response was acquired after step S20. In addition, in step S21, the component mounting device 130 may acquire a dummy value of the first command response of the other virtual unit of the first virtual unit and the second virtual unit, and add the dummy value to the first operation log 50. The dummy value is not a command response issued by the component mounting device 30, but a value set by a user or the like. The dummy value may be a preset value, or may be a value obtained through input by the user, etc.

Note that while Figure 5 illustrates an example in which the second operation log 150 is generated by the control unit 120, the second operation log 150 may also be generated by the component mounting device 130.

Figure 6 is a flowchart showing the operation of each unit (trouble analysis support method) of the analysis support device 100 according to this embodiment. Figure 6 can also be said to show a trouble analysis support method that supports the analysis of trouble in a component mounting device 30 by simulating the operation of the component mounting device 30, which is made up of one or more units. The following explanation uses the component mounting head unit 132 as an example. It is assumed that production data D1 and setting conditions D2 at the time a trouble occurs in the actual component mounting device 30 are input to the control unit 120.

As shown in Figure 6, the component mounting head unit 132 determines whether or not a command has been received from the control unit 120 (S101).

If the component mounting head unit 132 determines that a command has been acquired (Yes in S101), it determines the type of command (S102). If it determines that a command has not been received (No in S101), it waits until a command is received. Step S102 is an example of a second determination step.

Next, the component mounting head unit 132 extracts the corresponding command response from the first operation log 50 based on the command type determined in step S102 (S103). The component mounting head unit 132 may, for example, extract a command response (first command response) corresponding to the unit from the first operation log 50 in accordance with the determined command type, and issue the extracted command response as a second command response. Step S103 corresponds to step S12 shown in FIG. 5.

Next, the component mounting head unit 132 executes the command acquired in step S101 (S104). Step S104 corresponds to step S15 shown in Figure 5.

Next, the component mounting head unit 132 generates a command response to the acquired command from the extracted command response (S105). The component mounting head unit 132 generates the command response by replacing the command response in the steady state with the command response extracted in step S103.

Next, the component mounting head unit 132 issues the command response generated in step S105 to the control unit 120 (S106).

The above describes the operation of the component mounting head unit 132, but the other units also perform the process shown in Figure 6 in a similar manner.

The analysis support device 100 described above can simulate the commands issued in the manufacturing system 10 when a problem occurs in the component mounting device 30, and the command responses issued in response to those commands. If the second command response of any unit contains an error, the user can easily confirm whether the problem in the component mounting device 30 is due to a software bug by checking the commands issued to each unit around the time the second command response was issued. Furthermore, the analysis support device 100 can simulate whether countermeasures to the problem are effective, allowing for efficient consideration of countermeasures. In other words, the analysis support device 100 can assist the user in analyzing the cause of the problem.

(Other embodiments)
Although the trouble analysis support method and the like according to one or more aspects have been described above based on the embodiments, the present disclosure is not limited to these embodiments, etc. As long as they do not deviate from the spirit of the present disclosure, various modifications conceivable by a person skilled in the art to the present embodiments and forms constructed by combining components of different embodiments may also be included in the present disclosure.

For example, in the above embodiments, component mounting equipment has been used as an example of production equipment, but production equipment is not limited to component mounting equipment. Production equipment may be any equipment that performs specified processing or specified work on an object. Production equipment may be, for example, a solder application device, an inspection device, or other device.

Furthermore, in the above embodiments, each component may be configured with dedicated hardware, or may be realized by executing a software program appropriate for that component. Each component may also be realized by a program execution unit such as a CPU or processor reading and executing a software program recorded on a recording medium such as a hard disk or semiconductor memory.

Furthermore, the order in which each step in the flowchart is performed is merely an example to specifically explain the present disclosure, and orders other than those described above may also be used. Furthermore, some of the steps may be performed simultaneously (in parallel) with other steps, or some of the steps may not be performed at all.

Furthermore, the division of functional blocks in the block diagram is one example; multiple functional blocks may be realized as a single functional block, one functional block may be divided into multiple blocks, or some functions may be moved to other functional blocks. Furthermore, the functions of multiple functional blocks with similar functions may be processed in parallel or time-shared by a single piece of hardware or software.

Furthermore, the trouble analysis support device according to the above embodiments may be realized as a single device, or may be realized by multiple devices. When the trouble analysis support device is realized by multiple devices, the components of the trouble analysis support device may be distributed in any manner among the multiple devices. When the trouble analysis support device is realized by multiple devices, the communication method between the multiple devices is not particularly limited, and may be wireless communication or wired communication. Furthermore, wireless communication and wired communication may be combined between the devices.

Furthermore, these general or specific aspects may be realized as a system, method, integrated circuit, computer program, or non-transitory recording medium such as a computer-readable CD-ROM, or as any combination of a system, method, integrated circuit, computer program, or recording medium. The program may be pre-stored on the recording medium, or may be supplied to the recording medium via a wide area communication network, including the Internet.

Furthermore, each component described in the above embodiments may be implemented as software, or typically as an LSI, which is an integrated circuit. These components may be individually integrated into a single chip, or some or all of them may be integrated into a single chip. Here, we refer to LSIs, but depending on the level of integration, they may also be referred to as ICs, system LSIs, super LSIs, or ultra LSIs. Furthermore, the integration method is not limited to LSIs; dedicated circuits (general-purpose circuits that execute dedicated programs) or general-purpose processors may also be used. It is also possible to use FPGAs (Field Programmable Gate Arrays), which can be programmed after LSI manufacturing, or reconfigurable processors, which allow the connections or settings of circuit cells within an LSI to be reconfigured. Furthermore, if an integrated circuit technology that can replace LSIs emerges due to advances in semiconductor technology or other derivative technologies, that technology may naturally be used to integrate the components.

A system LSI is an ultra-multifunctional LSI manufactured by integrating multiple processing units onto a single chip. Specifically, it is a computer system comprising a microprocessor, ROM (Read Only Memory), RAM (Random Access Memory), etc. Computer programs are stored in the ROM. The system LSI achieves its functions when the microprocessor operates in accordance with the computer program.

Another aspect of the present disclosure may be a computer program that causes a computer to execute each of the characteristic steps included in the trouble analysis support method shown in either FIG. 5 or FIG. 6.

Also, for example, the program may be a program to be executed by a computer. Another aspect of the present disclosure may be a computer-readable, non-transitory recording medium on which such a program is recorded. For example, such a program may be recorded on a recording medium and distributed or circulated. For example, by installing the distributed program on a device having another processor and having that processor execute the program, it becomes possible to cause that device to perform each of the above processes.

This disclosure is useful for analysis devices that analyze production equipment problems.

REFERENCE SIGNS LIST 1 Trouble analysis support system 10 Manufacturing system 20 Control device 30, 130 Component mounting device 31, 131 Component supply unit 32, 132 Component mounting head unit 33, 133 Component recognition unit 34, 134 Axis control unit 35, 135 Board transport control unit 40 Storage unit 50 First operation log 100 Analysis support device 120 Control unit 150 Second operation log 200 Display device D1 Production data D2 Setting conditions

Claims (9)

A trouble analysis support method for supporting trouble analysis of a production facility by simulating the operation of the production facility composed of one or more units, comprising:
a command response acquisition step of acquiring, from a first operation log including an operation history at the time of occurrence of a trouble in the production equipment, a first command response which is a response from the one or more units to a first command issued to the one or more units;
a simulation step of simulating an operation of the production equipment based on the acquired first command response,
The simulation step includes:
a command issuing step of issuing a second command corresponding to the first command to one or more virtual units in a simulation corresponding to the one or more units;
a command execution step of executing the second command in the one or more virtual units;
a command response issuing step of issuing a second command response, which is a response from the one or more virtual units to the second command;
the command response issuing step issues the acquired first command response as the second command response;
moreover,
an operation log generation step of generating a second operation log including the second command response of each of the one or more virtual units;
a first determination step of determining whether the first operation log and the second operation log match,
If it is determined in the first determination step that the first operation log and the second operation log do not match, the first operation log is edited, and the simulation step is executed again based on the edited first operation log.
Troubleshooting support method. the one or more virtual units include a first virtual unit and a second virtual unit;
the first operation log includes a first command response corresponding to only one of the first virtual unit and the second virtual unit;
the edited first operation log includes an additionally acquired first command response that corresponds to the other virtual unit of the first virtual unit and the second virtual unit;
The trouble analysis support method according to claim 1 . the one or more virtual units include a first virtual unit and a second virtual unit;
the first operation log includes a first command response of only one of the first virtual unit and the second virtual unit;
the edited first operation log includes a dummy value of a first command response of the other virtual unit of the first virtual unit and the second virtual unit;
The trouble analysis support method according to claim 1 . Further, a second determination step of determining a type of the acquired second command is included,
In the command response issuing step, a first command response corresponding to the unit is extracted from the first operation log according to the determined type of the second command, and the extracted first command response is issued as the second command response.
The trouble analysis support method according to any one of claims 1 to 3 . the first command and the second command are commands generated based on production data related to production when a problem occurs in the production equipment and setting conditions of the one or more units.
The trouble analysis support method according to any one of claims 1 to 4 . A trouble analysis support method for supporting trouble analysis of a production facility by simulating the operation of the production facility composed of one or more units, comprising:
a command response acquisition step of acquiring, from a first operation log including an operation history at the time of occurrence of a trouble in the production equipment, a first command response which is a response from the one or more units to a first command issued to the one or more units;
a simulation step of simulating an operation of the production equipment based on the acquired first command response,
The simulation step includes:
a command issuing step of issuing a second command corresponding to the first command to one or more virtual units in a simulation corresponding to the one or more units;
a command execution step of executing the second command in the one or more virtual units;
a command response issuing step of issuing a second command response, which is a response from the one or more virtual units to the second command;
the command response issuing step issues the acquired first command response as the second command response;
Further, a second determination step of determining a type of the acquired second command is included,
In the command response issuing step, a first command response corresponding to the unit is extracted from the first operation log according to the determined type of the second command, and the extracted first command response is issued as the second command response.
Troubleshooting support method. A trouble analysis support device that supports trouble analysis of a production facility by simulating the operation of the production facility, the trouble analysis support device comprising one or more units,
an acquisition unit that acquires, from a first operation log including an operation history at the time of occurrence of a trouble in the production equipment, a first command response that is a response from the one or more units to a first command issued to the one or more units;
a simulation processing unit that simulates an operation of the production equipment based on the acquired first command response,
The simulation processing unit
issuing a second command corresponding to the first command to one or more virtual units in a simulation corresponding to the one or more units;
Executing the second command in the one or more virtual units;
issuing a second command response, the second command response being the one or more virtual units' response to the second command;
In issuing the second command response, the acquired first command response is issued as the second command response;
moreover,
generating a second operation log including the second command response for each of the one or more virtual units;
determining whether the first operation log and the second operation log match;
If it is determined that the first operation log and the second operation log do not match, the first operation log is edited, and a simulation is performed again based on the edited first operation log.
Troubleshooting support device. A trouble analysis support device that supports trouble analysis of a production facility by simulating the operation of the production facility, the trouble analysis support device comprising one or more units,
an acquisition unit that acquires, from a first operation log including an operation history at the time of occurrence of a trouble in the production equipment, a first command response that is a response from the one or more units to a first command issued to the one or more units;
a simulation processing unit that simulates an operation of the production equipment based on the acquired first command response,
The simulation processing unit
issuing a second command corresponding to the first command to one or more virtual units in a simulation corresponding to the one or more units;
Executing the second command in the one or more virtual units;
issuing a second command response, the second command response being the one or more virtual units' response to the second command;
In issuing the second command response, the acquired first command response is issued as the second command response;
Furthermore, a type of the acquired second command is determined;
extracting a first command response corresponding to the unit from the first operation log according to the determined type of the second command, and issuing the extracted first command response as the second command response;
Troubleshooting support device. A program for causing a computer to execute the trouble analysis support method according to any one of claims 1 to 6 .