JP2002144025A - Method for controlling trouble in casting line - Google Patents

Abstract

PROBLEM TO BE SOLVED: To scrupulously control an individual casting facility according as a defective state. SOLUTION: A continuous casting line (GD line) with a metallic mold is worked and the trouble time and trouble number of times in the individual facility in the GD line are detected. Then, the individual facility in the GD line is scrupulously controlled according as the defective state.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a casting line failure management method.

[0002]

2. Description of the Related Art In the conventional failure management of a casting line, an on-site person visually observes the operating condition of the casting line, monitors whether there is any abnormality in the operation of the line equipment, and clarifies that the operation is abnormal. We try to deal with facilities that we can understand.

[0003]

With such a management method, it is not possible to manage individual facilities in detail, and it is not possible to take appropriate measures.

SUMMARY OF THE INVENTION The present invention has been made in view of the foregoing, and an object of the present invention is to provide a method for managing a failure of a casting line in which individual casting facilities can be finely managed in accordance with the failure status.

[0005]

SUMMARY OF THE INVENTION According to the present invention, a casting line is operated to detect a failure time and the number of failures due to a malfunction in individual equipment of the casting line. This is a casting line failure management method that manages the failure status of the equipment.

[0006]

According to the present invention, the failure status of individual facilities of the casting line is managed in detail from the failure time and the number of failures due to malfunctions in individual facilities of the casting line.

[0007]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to embodiments shown in the drawings.

FIG. 5 shows an outline of a production line network system of a casting factory for aluminum casting, which includes a manufacturing office 11, a sand casting line 12, and a continuous casting line (hereinafter referred to as a GD line) as a casting line using dies. )13
And die-cast line (hereinafter referred to as DC line) 14
And a maintenance office 15, a core molding machine 16, a heat treatment unit 17,
Terminal devices (personal computers, abbreviated to personal computers, hereinafter) of the network are installed in the finishing unit 18, the machining unit 19, and the product storage unit 20, respectively. PC
Local Area Network (hereinafter referred to as LAN) 21
Connected by It is also connected to a value-added information network (VAN) 22 to take in external information.

In the manufacturing office 11, the product number, customer, manufacturing plant, casting line, unit weight, pouring material, additive, pouring amount, solidification (mold opening) time,
Various part number information 23 related to the production process such as a mold cooling time (air cooling, water cooling), a product cooling time, a deburring method, etc. is registered in a database.

This database includes order number information (collects and manages orders from customers according to delivery dates) together with the part number information 23, and production order plan information (production order plan while checking the line load based on the order information). ), Line load information (changes the load status of each casting line and core according to the production sequence plan) and production results information (manages the status of work-in-progress and products based on production results and shipping status) , Operation monitor (files information related to line operation, such as production line operation start and end time, person in charge, operation results, line stop reason, etc.), equipment management information (maintenance and maintenance of equipment related to production in the factory) Manage the situation).

The work standards (control conditions) registered in the part number information 23 at the manufacturing office 11 are transmitted to the respective casting lines 12, 1 through a terminal personal computer of the LAN 21 and a line control controller.
Directly instructed to machines such as 3,14. Also, a mold system sequence plan 24 created from the order information and line load information.
Or, according to the sand mold sequence plan 25, each casting line 12,
Machines such as 13, 14 are operated.

Further, the manufacturing office 11 displays information from order receipt to shipment (production lot completion status, etc.) on a display of a personal computer in real time, and manages production time information while monitoring the progress of each production line. Do.

Each of the automated casting lines 12, 13, 14 and the like directly obtains a work standard from a product number information database through a line control controller using a terminal personal computer of LAN 21 and operates according to the above-mentioned sequence plans 24, 25.
Further, the production results, operation rates, etc. of the respective casting lines 12, 13, 14 and the like are automatically totaled and recorded by the terminal personal computer of the LAN 21. At this time, the order plans 24 and 25 are automatically applied at the same time. In addition, the production line for manual lines and outsourced products is indicated by a person at the production site using a mouse to indicate digested lots in the detailed plan column displayed on the display of the personal computer. These are used as daily operation reports.

The maintenance office 15 searches a failure history table (Table 1), which will be described later, automatically created for each production line from the number of failures and time of each facility acquired from each production line. Maintenance and management of spare parts.

In the heat treatment section 17, the finishing section 18 and the machining section 19, when the movement between the steps is automatic, the product position is inputted from a line conveyor to a personal computer and is automatically stored. In the case of a manual line or outsourced product, a person at the production site gives an instruction using a mouse on the display of the personal computer according to the movement of the production lot.

The product storage unit 20 also uses a mouse to indicate a lot assigned to store and ship the product in lots in the detailed plan column displayed on the display of the personal computer (taking in shipping data).

Next, FIG. 6 shows a manufacturing office 11, a sand casting line 12, a maintenance office 15, a GD line 13, a core molding machine 16,
Each of the DC lines 14 is shown, and a terminal personal computer 31 connected by a LAN is installed at each location. 32 is a lamp port, 33 is a communication cable, 34 is an optical terminal,
Reference numeral 35 denotes an optical cable.

In the manufacturing office 11, input number means such as a keyboard 36 or a mouse 37 of the personal computer 31 is used to create a part number information database (register and change work standards, cycle times, etc.), create an order plan, and the like. In addition, management of work progress (production lot digestion status), quality control (acquisition of defect information for production lots, etc.), line operation management (production results, line failure status, operation rate, etc.) using the display 38 of the personal computer 31 Calculation etc.).

The sand casting line 12 is controlled by a line control controller 43 based on work standards and the like instructed through a LAN terminal personal computer 31. The operation status (production results, line failure status, etc.) of the sand casting line 12 is tabulated by the terminal personal computer 31 directly connected to the line control controller 43, and information is provided to the LAN.
11 and maintenance office 15

The GD line 13 is controlled by a line control controller 44 on the basis of work standards (type pouring amount, type temperature control, tilting speed, air suction time, coagulation time, etc.) instructed through the LAN terminal personal computer 31. Controlled. The operation status (production results, line failure status, etc.) of the GD line 13 is tabulated by the terminal personal computer 31 directly connected to the line control controller 44, and information is provided to the LAN. Manage.

Each of the DC lines 51 of 330 to 2000 t of the DC lines 14 is a line control controller based on a work standard or the like instructed through the LAN terminal personal computer 31a.
Controlled by 52. The operation status (production results, failure status, etc.) of each DC line 51 is determined by a line control controller.
Totals are provided by the personal computer 31a directly connected to 52 and information is provided to the LAN. Dedicated microcomputer 53 for die cast machine control
The 2500tDC line 54 equipped with a microcomputer is used to instruct control conditions to the die-casting machine body and to grasp the status of the machine body through its dedicated microcomputer 53, and to instruct peripheral equipment (product take-out device etc.) and grasp the line status by a personal computer This is performed by the controller 55 connected to 31b.

Next, FIG. 2 schematically shows a GD line (continuous casting line) 13 for transporting a plurality of types of dies in order, and includes a tilting machine 61, a mold opening / closing machine 62, and an automatic pouring machine 63. , Mold transfer device
64, 65, etc. are arranged.

The dies (upper and lower dies) are conveyed from a section to a section b by a traverser described later, and separated and removed by a mold opening / closing device 62. Only lower type is c by traverser
The product in the upper mold is dropped to the unloading device 66 at the part b, and the product cooling conveyor
It is carried out to 67.

The dies (upper die and lower die) that have been matched in the part b are conveyed to the d part of the tilting machine 61 by the mold feeder 68, and are automatically inserted into the die clamped in the d part. Pouring machine 63
As a result, the molten metal drawn from the holding furnace 69 is poured through a tub attached to the mold. At this time, the mold is rotated forward and backward within a range of 90 ° by the tilting machine 61, and the molten metal is cast into the mold while the air in the mold is sucked out.

After the feeder effect is completed, the mold is released from the clamp and discharged to the portion e of the mold transfer device 64, is transferred to the portion f by the mold transfer device 64, and is further transferred by the mold feeder 70. The mold is conveyed to the g portion of the device 65, where the mold is cooled by the water injection means 71 as a cooling facility, the air cooling fan 72, and the water spray nozzle 73, and then carried out to the a portion.

A mold setting device 74 provided outside the continuous casting line is for efficiently changing the molds as necessary, and makes the prepared molds stand by at a position h.
After unloading the mold from the portion e in the continuous casting line to the position i, the mold setup device 74 is moved to transfer the mold moved from the position h to the position i into the portion e.

Next, FIG. 3 and FIG. 4 show a separator. In this separator, dies (upper die 81 and lower die 82) are connected to each other in FIG.
Traverser 83 transported between parts b and b or between parts b and c
And the mold opening / closing device 62 that moves the upper mold 81 up and down to open and close the lower mold 82.

An upper die 81 is attached to a frame 84 of the die switch 62.
Radiation thermometer sensors S1, S2, S3, S4 for detecting the temperature in each mold when the lower mold 82 and the lower mold 82 are opened are provided. The mold temperature information detected by the radiation thermometer sensors S1, S2, S3, S4 is fed back to a cooling facility such as the water injection means 71 as a cooling time.

The mold opening / closing device 62 is provided with a platen 87 which is moved up and down by a guide rod 86 by an elevating cylinder 85 on an upper portion of a frame 84. An upper mold clamp 89 which is opened and closed by a clamp cylinder 88 is provided on the platen 87. Is installed.

The traverser 83 includes a roller 92 for loading and unloading a lower die on a carriage 91 driven by a motor.
A lower mold clamp 93 that is opened and closed by a clamp cylinder 88 to fix the upper lower mold 82 is provided.

This separator (the mold switch 62 and the traverser
At 83), as shown in FIG. 3, when the upper mold 81 and the lower mold 82 in the matching state are carried in from the direction of the arrow to the position shown by the two-dot chain line (part b in FIG. 2), the upper mold 81 becomes Platen
At 87, it is gripped by the upper die clamp 89 and lift cylinder 85
Is lifted as shown by the solid line, and separated from the lower mold 82.

Further, the lower mold 82 is moved by a traverser 83 as shown in FIG.
The core is moved to the core setting position (portion c in FIG. 2) indicated by the solid line, and the core is inserted into the lower die 82 at the solid line position.

Next, with reference to FIG. 1, a method for managing a failure of a casting line according to the present invention will be described for the automated GD line 13.

As described above, the individual equipment of the GD line 13 is operated by receiving an operation command from the line control controller 44 connected to the LAN terminal personal computer 31 for acquiring the work standard of the part number information database ( FIG. 1A,
B).

The individual equipment of the GD line 13 includes limit switches provided at various position detection locations, solenoid valves provided in a fluid pressure actuator control circuit, and a traverser 83.
And the operation timing of a motor or the like for driving the tilting machine 61 is electrically detected and taken into the personal computer 31 on the GD line 13 (C).

The personal computer 31 compares the operation command with the operation detection (D), and counts a time error (referred to as a failure time) of the operation detection with respect to the operation command and a number of times (E).

As shown in Table 1 below, the personal computer 31
For each facility of the D-line 13, the failure time and the number of failures are displayed separately for the day and the cumulative number, and the data is automatically calculated from the data based on a reference value different depending on the casting line or facility. A GD line failure history table displaying the degree of failure (warning sign) is automatically created (F).

This failure history table is filed not only on the GD line 13 but also on the personal computer 31 such as the manufacturing office 11 and the maintenance office 15 through the LAN 21 and the display 38 is displayed.
Are also displayed as necessary, so as to be useful for process control and quality control (G).

For example, while checking the failure tendency (property peculiar to the equipment) and the necessity of repair for the failure displayed in the failure history table, the failure history of each equipment is dealt with in detail, and the failure history is checked. Address current or future failures based on past malfunction trends and levels displayed in the table.

In particular, from the time error of the operation detection with respect to the operation command and the total number of times of operation detection, it is possible to know the operation errors accumulated over a long period of time. So, by comparing the cumulative amount and the current day, for example, it is possible to determine whether the malfunction was caused by natural deterioration due to aging of the equipment or suddenly caused by some kind of equipment failure. Understand malfunction trends that cannot be understood only by themselves and deal with current or future failures.

When the degree of malfunction is high, a warning is issued by a buzzer, a lamp, or the like of a personal computer, a controller, or the like, and prompt measures are taken.

Although the failure history table of Table 1 shows warning signs 0 to 3, it is preferable to use, for example, warning signs 0 to 5 as necessary. Warning sign 0 means "no abnormality", warning sign 1 means "needs attention", warning sign 2 means "needs confirmation", and warning sign 3
Means "requires repair in the near future", warning sign 4 means "requires repair in the day", and warning sign 5 means "requires repair immediately after stopping the line".

These warning signs are set to the above-mentioned reference values so that the numerical value is reduced in equipment that has little effect on the operation of the casting line even if malfunctions occur frequently. Also, the reference value is set so that the numerical value becomes higher in the equipment that has a significant effect on the line operation.

[0044]

[Table 1]

Table 1 shows, as an example, a failure history of equipment such as the separator (the mold switch 62 and the traverser 83) shown in FIGS. 3 and 4. SW is a manual switch, LS is a limit switch, SOL is a solenoid of a solenoid valve used in a fluid pressure control circuit of a fluid pressure actuator (such as an air cylinder), and MS is a switch of an electric motor.

In the above embodiment, the GD line 13 was described as a casting line. However, the present invention is not limited to the GD line 13, and the sand casting line 1
2. It is preferable to create the failure history table for other casting lines such as the DC line 14.

[0047]

According to the present invention, the state of failure of individual facilities of the casting line can be finely managed from the failure time and the number of failures due to malfunctions in individual facilities of the casting line.

[Brief description of the drawings]

FIG. 1 is a configuration diagram illustrating a casting line failure management method of the present invention.

FIG. 2 is a plan view of a GD line on which the failure management method is performed.

FIG. 3 is a front view showing the mold switch on the GD line.

FIG. 4 is a side view of the same type switchgear.

FIG. 5 is a schematic view showing a casting LAN.

FIG. 6 is a diagram showing a specific configuration example of the LAN.

[Explanation of symbols]

 13 GD line as a casting line

Claims (1)

[Claims] 1. A casting line is operated to detect a failure time and the number of failures due to a malfunction in individual equipment of the casting line, and to manage a failure state of individual equipment of the casting line from the failure time and the number of failures. A failure management method for a casting line.