Sheet metal factory processing system

The present application is a continuation application of pending U.S. patent application Ser. No. 10/985,050, filed on Nov. 10, 2004, which claims the benefit of U.S. provisional Patent Application No. 60/519,272, filed Nov. 13, 2003, the contents of which are expressly incorporated by reference herein in their entireties.

The present invention relates to a sheet metal factory processing system, which nests part data in a material sheet, and processes it by a processing machine.

Conventionally, in the sheet metal factory processing system constituted by a production management apparatus and a sheet metal factory processing installation, the production management apparatus generates a manufacturing designation (manufacturing arrangement), and the sheet metal factory processing installation execute a processing schedule on the basis of the manufacturing designation.

In some conventional sheet metal factory processing system of this type, when a production management apparatus generates a manufacturing designation, the production management apparatus also generates a processing schedule including nesting of part data and a CAM process and gives the manufacturing designation including the processing schedule to sheet metal factory processing installation to cause the sheet metal factory processing installation to perform a schedule operation according to an executable processing schedule based on the manufacturing designation.

In some sheet metal factory processing system of this type, a production management apparatus merely generates a manufacturing designation, a sheet metal factory processing installation which receives the manufacturing designation from the production management apparatus generates a processing schedule including nesting of part data and a CAM process from the manufacturing designation by using a controller and performs a schedule operation according to the processing schedule (for example, see Japanese Patent Application Laid-Open (JP-A) No. 11-10491).

However, both the conventional sheet metal factory processing systems have various problems.

That is, in the sheet metal factory processing system in which the production management apparatus also generates a processing schedule, after a manufacturing designation (manufacturing arrangement) including the processing schedule is once given from the production management apparatus to the sheet metal factory processing installation, the sheet metal factory processing installation performs only a schedule operation on the basis of the given manufacturing designation.

For this reason, in the schedule operation performed by the sheet metal factory processing installation on the basis of the manufacturing designation, for example, it is assumed that a change such as an addition must be made to the manufacturing designation by the production management apparatus. In this case, even though the production management apparatus tries to change the processing schedule on the basis of the change of the manufacturing designation, the production management apparatus cannot easily change the processing schedule while correcting the processing schedule which has been given to the sheet metal factory processing installation in advance because the progress of the schedule operation, which is being executed by the sheet metal factory processing installation is unknown.

Therefore, for the production management apparatus the sheet metal factory processing installation cannot be easily and smoothly operated on the basis of the desired manufacturing designation. In addition, since the sheet metal factory processing installation is not smoothly operated on the basis of the manufacturing designation, an unnecessary waiting time cannot be easily shortened, and the operating rate and the production efficiency of the sheet metal factory processing installation cannot easily improved.

Furthermore, in a sheet metal factory processing system in which a sheet metal factory processing installation generates a processing schedule by using a controller, the data processing ability of the controller is inevitably inferior to the data processing ability of the production management apparatus.

For this reason, for example, the sheet metal factory processing system cannot easily cope with a case in which a large amount of data processing is required to generate a processing schedule including nesting of part data and a CAM process for a manufacturing designation given by the production management apparatus as in multi-product multi-volume production or a case in which necessary data processing must be frequently performed to manufacturing designations sequentially given by the production management apparatus as in single-product uniform production.

Therefore, for the production management apparatus, the sheet metal factory processing installation cannot be easily and smoothly operated on the basis of a desired manufacturing designation. Since the sheet metal factory processing installation is not smoothly operated on the basis of the manufacturing designation, an unnecessary waiting time cannot be easily shortened, and the operating rate and the production efficiency of the sheet metal factory processing installation cannot be easily improved.

The present invention has been made to solve the above problem, and has as its object to provide a sheet metal factory processing system which can smoothly operate a sheet metal factory processing installation based on a desired manufacturing designation for a production management apparatus and which can improve the operating raze and the production efficiency of the sheet metal factory processing installation.

A first aspect of the invention provides a sheet metal factory processing system comprising a production management apparatus which generates a processing schedule based on sheet processing data obtained by nesting according to a manufacturing designation to manage the processing schedule in each unit of material sheets; and a sheet metal factory processing installation which is mutually connected to the production management apparatus through a communication network to execute the processing schedule received from the production management apparatus.

A second aspect of the invention provides the sheet metal factory processing system according to the first aspect of the invention, wherein, before all the processing schedules based on the manufacturing designation are completely executed by the sheet metal factory processing installation, when one selected from an addition or a change is made to the manufacturing designation, the production management apparatus integrates an unexecuted processing schedule included in the manufacturing designation with the content of the selected one from the addition or the change to regenerate a processing schedule based on the sheet processing data obtained by nesting according to a new manufacturing designation.

A third aspect of the invention provides a sheet metal factory processing system comprising a production management apparatus which generates a processing schedule based on sheet processing data obtained by nesting according to a manufacturing designation to manage the processing schedule in each unit of material sheets; and a sheet metal factory processing installation which is mutually connected to the production management apparatus through a communication network to execute the processing schedule received from the production management apparatus, and wherein the production management apparatus transmits the processing schedule for each of the material sheets to every processing schedule requests from the sheet metal factory processing installation.

A fourth aspect of the invention provides the sheet metal factory processing system according to the third aspect of the invention, wherein, before all the processing schedules based on the manufacturing designation are completely executed by the sheet metal factory processing installation, when one selected from an addition or a change is made to the manufacturing designation, the production management apparatus integrates an unexecuted processing schedule included in the manufacturing designation with the content of the selected one from the addition or the change to regenerate a processing schedule based on the sheet processing data obtained by nesting according to a new manufacturing designation.

A fifth aspect of the invention provides a sheet metal factory processing system comprising a production management apparatus which generates a processing schedule based on sheet processing data obtained by nesting according to a manufacturing designation to manage the processing schedule in each unit of material sheets; and a sheet metal factory processing installation which is mutually connected to the production management apparatus through a communication network to execute the processing schedule received from the production management apparatus, and wherein in response to a processing schedule request from the sheet metal factory processing installation, the production management apparatus transmits the processing schedule of one next material sheet to the sheet metal factory processing installation at a timing when processing end estimated time of the preceding material sheet in the sheet metal factory processing installation and convey-in preparation completion estimated time of the next material sheet in the sheet metal factory processing installation are synchronized with each other.

A sixth aspect of the invention provides the sheet metal factory processing system according to the fifth aspect of the invention, wherein, before all the processing schedules based on the manufacturing designation are completely executed by the sheet metal factory processing installation, when one selected from an addition or a change is made to the manufacturing designation, the production management apparatus integrates an unexecuted processing schedule included in the manufacturing designation with the content of the selected one from the addition or the change to regenerate a processing schedule based on the sheet processing data obtained by nesting according to a new manufacturing designation.

A seventh aspect of the invention provides a sheet metal factory processing system comprising a production management apparatus which generates a processing schedule based on sheet processing data obtained by nesting according to a manufacturing designation to manage the processing schedule in each unit of material sheets; and a plurality of sheet metal factory processing installations which are connected to the production management apparatus through a communication network to independently execute the processing schedules received from the production management apparatus.

A eighth aspect of the invention provides the sheet metal factory processing system according to the seventh aspect of the invention, wherein, before all the processing schedules based on the manufacturing designation are completely executed by each of the sheet metal factory processing installations, when one selected from an addition or a change is made to the manufacturing designation, the production management apparatus integrates an unexecuted processing schedule included in the manufacturing designation with the content of the selected one from the addition or the change to regenerate a processing schedule based on the sheet processing data obtained by nesting according to a new manufacturing designation.

A ninth aspect of the invention provides a sheet metal factory processing system comprising a production management apparatus which generates a processing schedule based on sheet processing data obtained by nesting according to a manufacturing designation to manage the processing schedule in each unit of material sheets; and a plurality of sheet metal factory processing installations which are connected to the production management apparatus through a communication network to independently execute the processing schedules received from the production management apparatus, and wherein the production management apparatus transmits the processing schedule for each of the material sheets to the every processing schedule requests from each of the sheet metal factory processing installations.

A tenth aspect of the invention provides the sheet metal factory processing system according to the ninth aspect of the invention, wherein, before all the processing schedules based on the manufacturing designation are completely executed by each of the sheet metal factory processing installations, when one selected from an addition or a change is made to the manufacturing designation, the production management apparatus integrates an unexecuted processing schedule included in the manufacturing designation with the content of the selected one from the addition or the change to regenerate a processing schedule based on the sheet processing data obtained by nesting according to a new manufacturing designation.

A eleventh aspect of the invention provides a sheet metal factory processing system comprising a production management apparatus which generates a processing schedule based on sheet processing data obtained by nesting according to a manufacturing designation to manage the processing schedule in each unit of material sheets; and a plurality of sheet metal factory processing installations which are connected to the production management apparatus through a communication network to independently execute the processing schedules received from the production management apparatus, and wherein in response to a processing schedule request from each of the sheet metal factory processing installations, the production management apparatus transmits the processing schedule of one next material sheet to the corresponding sheet metal factory processing installation at a timing when processing end estimated time of the preceding material sheet in the corresponding sheet metal factory processing installation and convey-in preparation completion estimated time of the next material sheet in the sheet metal factory processing installation are synchronized with each other.

A twelfth aspect of the invention provides the sheet metal factory processing system according to the eleventh aspect of the invention, wherein, before all the processing schedules based on the manufacturing designation are completely executed by each of the sheet metal factory processing installations, when one selected from an addition or a change is made to the manufacturing designation, the production management apparatus integrates an unexecuted processing schedule included in the manufacturing designation with the content of the selected one from the addition or the change to regenerate a processing schedule based on the sheet processing data obtained by nesting according to a new manufacturing designation.

A thirteenth aspect of the invention provides a processing schedule management method wherein a processing schedule of a material sheet obtained by nesting a part on the basis of a manufacturing designation, the processing schedule being obtained by a sheet metal factory processing installation, is managed in each unit of the sheets.

A fourteenth aspect of the invention provides a processing schedule management method wherein depending on one selected from an addition or a change, an unprocessed part in a processing schedule based on a previous manufacturing designation is nested in a material sheet again while being included in the content of one selected from the addition or the change of the manufacturing designation, so that a subsequent processing schedule can be reformed.

A fifteenth aspect of the invention provides a processing schedule management method wherein a part unprocessed in a processing schedule based on a previous manufacturing designation cannot be processed due to a state of a sheet metal factory processing installation, the unprocessed part is nested in another material sheet again, so that a subsequent processing schedule is reformed.

A sixteenth aspect of the invention provides a processing schedule management method wherein in order to synchronize a convey-out operation of a product included in a processing schedule which is being executed in an sheet metal factory processing installation with a convey-out operation of a material used in a next processing schedule, the next processing schedule is started.

A seventeenth aspect of the invention provides a processing schedule management method wherein when a material sheet used in a processing schedule based on a previous manufacturing designation has not been processed, the processing schedule based on the previous manufacturing designation is canceled depending on an addition to the manufacturing designation, and the added part is allocated to the material sheet to execute processing.

A eighteenth aspect of the invention provides a processing schedule management method wherein when a material sheet used in a processing schedule based on a previous manufacturing designation is being processed, processing of an unprocessed part of parts arranged on the material sheet is canceled depending on an addition to the manufacturing designation, and the added part is allocated to an unused region including an arrangement position of the unprocessed part on the material sheet to execute processing.

A nineteenth aspect of the invention provides a processing schedule management method wherein when a material sheet used in a processing schedule based on a previous manufacturing designation has been processed in a sheet metal factory processing installation, depending on an addition to the manufacturing designation, the added part is allocated to the rest of the blank region of the material sheet on which the part is processed to execute processing.

A twentieth aspect of the invention provides a program which causes a computer arranged in one selected from a production management apparatus or a sheet metal factory processing installation to execute a process including the step of, depending on one selected from an addition or a change of a manufacturing designation, including a part unprocessed in a processing schedule based on a previous manufacturing designation in a content of one selected from the addition or the change of the manufacturing designation; and the step of nesting a content of the addition or the change of the manufacturing designation including the unprocessed part in a material sheet again.

A twenty-first aspect of the invention provides a program which causes a computer arranged in one selected from a production management apparatus or a sheet metal factory processing installation to execute a process including the step of deciding a change in state of the sheet metal factory processing installation; and the step of, depending on a change in state at which processing of an unprocessed part cannot be performed in a processing schedule based on a previous manufacturing designation in the sheet metal factory processing installation, nesting the unprocessed part in another material sheet.

The invention, as described above, includes a production management apparatus which generates a processing schedule based on a manufacturing designation to manage the processing schedule in each unit of material sheets and a sheet metal factory processing installation which is mutually connected to the production management apparatus through a communication network to execute the processing schedule received from the production management apparatus. For this reason, for the production management apparatus, the sheet metal factory processing installation can be smoothly operated on the basis of a desired manufacturing designation, and the operating rate and the production efficiency of the sheet metal factory processing installation can be advantageously improved.

FIG. 1 is a schematic block diagram showing a first embodiment of a sheet metal factory processing system according to the invention;

FIG. 2 is a schematic diagram showing an arrangement of peripheral devices in the sheet metal factory processing system in FIG. 1 ;

FIG. 3 is a table showing an example of a manufacturing designation in the sheet metal factory processing system in FIG. 1 ;

FIG. 4 is a table showing a blank layout result of a processing schedule based on the manufacturing designation in FIG. 3 ;

FIG. 5 is a table showing a processing schedule for each material sheet based on the manufacturing designation in FIG. 3 ;

FIG. 6 is a table showing a reserved actual result of the processing schedule;

FIG. 7 is a table showing an example of an additional manufacturing designation;

FIG. 8 is a table showing a blank layout result of a processing schedule based on the additional manufacturing designation;

FIG. 9 is a table showing a processing schedule for each material sheet based on the additional manufacturing designation;

FIG. 10 is a schematic layout diagram showing a first example of an interrupt function in the sheet metal factory processing system in FIG. 1 ;

FIG. 11 is a schematic layout diagram showing a second example of the interrupt function in the sheet metal factory processing system in FIG. 1 ;

FIG. 12 is a schematic layout diagram showing a third example of the interrupt function in the sheet metal factory processing system in FIG. 1 ;

FIG. 13 is a schematic layout diagram showing a fourth example of the interrupt function in the sheet metal factory processing system in FIG. 1 ;

FIG. 14 is a schematic layout diagram showing a fifth example of the interrupt function in the sheet metal factory processing system in FIG. 1 ;

FIG. 15 is a schematic diagram of a material sheet showing a processing example to which the interrupt function in FIG. 14 is applied;

FIG. 16 is a schematic layout diagram showing a sixth example of the interrupt function in the sheet metal factory processing system in FIG. 1 ;

FIG. 17 is a schematic diagram of a material sheet showing a processing example to which the interrupt function in FIG. 16 is applied;

FIG. 18 is a schematic block diagram showing a second embodiment of a sheet metal factory processing system according to the invention;

FIG. 19 is a flow chart showing an operation of a job controller in the sheet metal factory processing system in FIG. 18 ;

FIG. 20 is a flow chart showing an operation of a new arrangement process in the flow of the job controller;

FIG. 21 is a flow chart showing an operation of a schedule forming process in the flow of the job controller;

FIG. 22 is a flow chart showing an operation of a processing possible/impossible decision process in the flow of the schedule forming process;

FIG. 23 is a flow chart showing an operation of a nesting process in the flow of the schedule forming process;

FIG. 24 is a flow chart showing an operation of an interrupt arrangement process in the flow of the job controller;

FIG. 25 is a flow chart showing an operation of an additional nesting process in the flow of the interrupt arrangement process;

FIG. 26 is a flow chart showing an operation of a schedule substituting process in the flow of the job controller;

FIG. 27 is a flow chart showing an operation of a schedule reforming process in the flow of the job controller;

FIG. 28 is a flow chart showing an operation of a schedule transmitting process in the flow of the job controller;

FIG. 29 is a flow chart showing an operation of a halfway interrupt response process in the flow of the job controller;

FIG. 30 is a flow chart showing an operation of cell controller in the sheet metal factory processing system in FIG. 18 ;

FIG. 31 is a flow chart showing an operation of a cell operation task in the flow of the cell controller;

FIG. 32 is a flow chart showing an operation of a schedule request process in the flow of the cell operation task;

FIG. 33 is a flow chart showing an operation of a halfway interrupts confirming process in the flow of the cell operation task;

FIG. 34 is a flow chart showing an operation of an ending process in the flow of the cell operation task;

FIG. 35 is a schematic block diagram showing a third embodiment of the sheet metal factory processing system according to the invention;

FIG. 36 is a schematic diagram showing an arrangement of peripheral devices in the sheet metal factory processing system in FIG. 35 ;

FIG. 37 is a schematic block diagram showing a fourth embodiment of the sheet metal factory processing system according to the invention; and

FIG. 38 is a schematic diagram showing an arrangement of automatic warehouse installation and sheet metal factory processing installations.

Embodiments of the invention will be described below with reference to the accompanying drawings.

FIG. 1 is a schematic block diagram showing a first embodiment of a sheet metal factory processing system according to the invention. In the sheet metal factory processing system 101 , a production management apparatus 110 and a sheet metal factory processing installation 130 are communicably combined to each other, and the sheet metal factory processing installation 130 executes the processing schedule on the basis of a manufacturing designation (manufacturing arrangement) generated by the production management apparatus 110 .

The production management apparatus 110 includes a production management unit 111 , a process scheduler (progress management) 112 , a dynamic nesting & CAM processing unit 113 , and a job controller 114 . The production management apparatus 110 is connected to a network 120 .

The production management unit 111 performs various processes required for production management and generates a necessary manufacturing designation on the basis of the production management to manage the manufacturing designation.

The process scheduler (progress management) 112 generates a processing schedule executed by the sheet metal factory processing installation 130 on the basis of the manufacturing designation obtained by the production management unit 111 to manage the processing schedule.

The dynamic nesting & CAM processing unit 113 performs a blank layout process for nesting part data in a material sheet and a CAM process for generating processing data of the material sheet in generation of the processing schedule by the process scheduler (progress management) 112 .

The job controller 114 exchanges various data with a controller 131 of the sheet metal factory processing installation 130 through the network 120 . The job controller 114 exchanges various necessary data with the respective components of the production management apparatus 110 .

The sheet metal factory processing installation 130 includes the controller 131 , a CNC device 135 , a processing machine 136 , a line control box 137 , and a peripheral device 140 . In the sheet metal factory processing installation 130 , the controller 131 is connected to the network 120 .

The controller 131 exchanges various data with the job controller 114 of the production management apparatus 110 through the network 120 . Additionally, the controller 131 exchanges various necessary data with the components of the sheet metal factory processing installation 130 .

The controller 131 includes a schedule request unit 132 which requests a processing schedule to the job controller 114 of the production management apparatus 110 and which receives the processing schedule from the job controller 114 , a cell control operation and DNC transfer unit 133 , and a inventory management (storage and peripheral control) unit 134 .

Data and a program of software instructions which are described herein as being stored are stored on a computer readable medium. A computer readable medium is a tangible medium upon which data and a program of software instructions can be stored and from which data and a program of software instructions can be read.

The CNC device 135 forms an executable NC data on the basis of the processing schedule received by the controller 131 from the job controller 114 in response to the schedule request in consideration of processing condition and tooling information.

The CNC device 135 reads processing data of a part designated by the processing schedule to control the processing machine 136 .

As the processing machine 136 , for example, a punching (punching press machine), a laser (laser processing machine), or the like is applied. The processing machine 136 executes a required sheet metal processing (sheet processing) in cooperation with the peripheral device 140 on the basis of NC data from the CNC device 135 .

In execution of desired sheet metal processing (sheet processing) by the processing machine 136 , the line control box 137 operates the peripheral device 140 in cooperation with the processing in machine 136 on the basis of the processing schedule received by the controller 131 from the job controller 114 in response to the schedule request.

FIG. 2 is a schematic diagram showing an arrangement of the peripheral device 140 . The peripheral device 140 includes storages such as a material storage 141 and a product storage 142 which are arranged around the processing machine 136 , waiting spaces such as a loading buffer 143 and a unloading buffer 144 arranged adjacent to these storages, a loading/unloading shuttle 145 arranged adjacent to the processing machine 136 , and a single-sheet pickup and conveying device 146 .

As the single-sheet pickup and conveying device 146 , a travelling region along a direction in the waiting spaces are aligned is schematically shown in FIG. 2 . In the single-sheet pickup and conveying device 146 , a carrier which has a large number of vacuum pads covering a plane having a size corresponding to the size of a material sheet is travelably supported along a traveling rail arranged above such that the vacuum pads can be vertically moved.

In the single-sheet pickup and conveying device 146 , the carrier is designed to be able to move forward from the traveling region along the traveling rail to the side and to move backward into the traveling region.

For this reason, the peripheral device 140 , as shown in FIG. 2 , can execute various operations, which handle a material sheet.

More specifically, the single-sheet pickup and conveying device 146 can pick up one material sheet front the material storage 141 , can convey the metal sheet, and can place the metal sheet on the loading buffer 143 .

Additionally, the single-sheet pickup and conveying device 146 can pick up a material sheet from the loading buffer 143 , and can convey the metal sheet, and can place the metal sheet on the loading/unloading shuttle 145 .

More over, the loading/unloading shuttle 145 can load the material sheet on the processing machine 136 .

The loading/unloading shuttle 145 can unload the processed sheet (product) from the processing machine 136 .

The single-sheet pickup and conveying device 146 can pick up one processed sheet (product) from the loading/unloading shuttle 145 , can convey the processed sheet, and can place the processed sheet (sort and accumulate) on the unloading buffer 144 .

The single-sheet pickup and conveying device 146 can pick one processed sheet from the unloading buffer 144 , can convey the processed sheet, and can store the processed sheet on the product storage 142 .

The single-sheet pickup and conveying device 146 can include only one carrier such that the single carrier can be commonly used in a single-sheet pickup and conveying operation of a material sheet frown the material storage 141 to the processing machine 136 and a single-sheet pickup and conveying operation of the single sheet from the processing machine 136 to the product storage 142 .

In the single-sheet pickup and conveying device 146 , a carrier which performs a single-sheet pickup and conveying operation of a material sheet from the material storage 141 to the processing machine 136 and a carrier which performs a single-sheet pickup and conveying operation of the material sheet from the processing machine 136 to the product storage 142 can be independently arranged.

The dynamic nesting & CAM processing unit 113 of the production management apparatus 110 has a processing time simulation function which calculates required time from when the processing is started after one material sheet is loaded on the processing machine 136 to when the processing is ended.

The production management apparatus 110 records, as data, the actual time required for delivery, i.e., time until a material sheet is picked up from the material storage 141 and placed on the loading/unloading shuttle 145 through the loading buffer 143 in the past.

The controller 131 of the sheet metal factory processing installation 130 is designed to generate the next schedule request immediately after one material sheet is conveyed out of the loading buffer 143 to the loading/unloading shuttle 145 to make the loading buffer 143 empty.

The production management apparatus 110 is designed such that, when the job controller 114 receives the schedule request from the controller 131 , the production management apparatus 110 gives the processing schedule of one material sheet to the sheet metal factory processing installation 130 at a timing when processing end estimated time and convey-in preparation completion estimated time are synchronized with each other such that preparation for an operation for conveying the next material sheet into the processing machine 136 is completed at estimated time at which processing end of a material sheet which is being processed by the processing machine 136 .

More specifically, the production management apparatus 110 is designed to give the processing schedule of the next material sheet at time (“m minutes before the processing end estimated time”) obtained by calculating back time required for delivery of the next material sheet estimated, with reference to past records, from the processing end estimated time calculated by the processing time simulation function with respect to the material sheet which is being processed.

The operation of the embodiment described above will be described below with reference to tables shown in FIGS. 3 to 9 .

The production management unit 111 of the production management apparatus 110 generates a necessary manufacturing designation on the basis of a production management. The manufacturing designation is expressed by, for example, “Five parts P 1 , six parts P 2 , two parts P 3 , and one part P 4 will be manufactured by a laser processing machine until a delivery date: September 20”. The table shown in FIG. 3 expresses the manufacturing designation.

On the basis of the manufacturing designation, process scheduler (progress management) 112 generates a processing schedule through a blank layout process and a CAM process performed by the dynamic nesting & CAM processing unit 113 .

More specifically, as shown in FIG. 4 , the types (materials, thicknesses, sizes, and the like) of material sheets to be used, the necessary number of material sheets, and a processing machine (for example, #1 laser) are decided to determine a processing schedule.

As shown in FIG. 5 , the determined processing schedule is divided in each unit of material sheets, so that a processing schedule for each material sheet is completed on the basis of the manufacturing designation.

First, when a processing schedule of the first material sheet S 1 - 1 is transmitted from the job controller 114 to the controller 131 , the controller 131 of the sheet-metal factory processing installation 130 reserves the #1 laser processing machine 136 according to the processing schedule and causes the processing machine 136 to perform a processing of the first material sheet S 1 - 1 in cooperation with the peripheral device 140 .

The first material sheet S 1 - 1 is delivered from the material storage 141 and conveyed toward the loading/unloading shuttle 145 through the loading buffer 143 . The moment the loading buffer 143 becomes empty, the controller 131 transmits the next schedule request to the job controller 114 .

When the job controller 114 receives the schedule request, the production management apparatus 110 transmits a processing schedule of a second material sheet S 1 - 2 from the job controller 114 to the controller 131 at a timing when processing end estimated time of the first material sheet S 1 - 1 is synchronized with convey-in preparation completion estimated time of the second material sheet S 1 - 2 .

In response to the processing schedule, the controller 131 of the sheet metal factory processing installation 130 reserves the #1 laser processing machine 136 according to the processing schedule and causes the #1 laser processing machine 136 to perform a sheet processing of the second material sheet S 1 - 2 in cooperation with the peripheral device 140 .

The states of a processing schedules managed by the process scheduler (progress management) 112 are shown in FIG. 6 . More specifically, when reserving states are considered, the first and second material sheets S 1 - 1 and S 1 - 2 have been reserved, and the third and the subsequent material sheets S 1 - 3 , . . . are not processed.

In this state, when the production management unit 111 of the production management apparatus 110 changes (including addition) a present manufacturing designation on the basis of the production management, i.e., for example, when a manufacturing designation given by “Four parts P 5 will be manufactured by a laser processing machine until a delivery date: September 20.” is added, as shown in FIG. 7 , a new manufacturing designation for the part P 5 is added to the current manufacturing designation (see FIG. 3 ) for the parts P 1 to P 4 to regenerate a manufacturing designation.

On the basis of the regenerated manufacturing designation and a progress state of the processing schedule at the present, the process scheduler (progress management) 112 obtains a blank layout process and a CAM process performed by the dynamic nesting & CAM processing unit 113 to regenerate a processing schedule.

More specifically, as shown in FIG. 7 with respect to the additional manufacturing designation given by “Four parts P 5 will be manufactured by a laser processing machine until a delivery date: September 20”, the types of material sheets to be used, the necessary number of material sheets, and a processing machine are determined. The manufacturing designation is integrated with an unexecuted processing schedule shown in FIG. 6 to determine, as shown in FIG. 8 , a processing schedule required after the present time in the regenerated manufacturing designation.

As shown in FIG. 9 , below the table of the reserved material sheets S 1 - 1 to S 1 - 2 until the present time, the determined processing schedule is divided in each unit of material sheets, so that a processing schedule for each material sheet required after the present time can be completed on the basis of the regenerated manufacturing designation.

When the job controller 114 receives the next schedule request from the controller 131 , the production management apparatus 110 transmits a processing schedule of the third material sheet S 3 - 1 from the job controller 114 to the controller 131 at a timing when processing end estimated time of the second material sheet S 1 - 2 is synchronized with a convey-in preparation completion estimated time of the third material sheet S 3 - 1 .

In response to the processing schedule, the controller 131 of the sheet metal factory processing installation 130 reserves the #1 laser processing machine 136 according to the processing schedule and causes the #1 laser processing machine 136 to perform a sheet processing of the third material sheet S 3 - 1 in cooperation with the peripheral device 140 .

Similarly, when a sheet processing of a final material sheet S 5 - 1 is ended, all required sheet metal factory processings (sheet processings) based on the current manufacturing designation (see FIG. 7 ) including halfway addition are ended.

As described above, in the sheet metal factory processing system 101 , the process scheduler (progress management) 112 of the production management apparatus 110 manages processing schedules based on the manufacturing designation in each unit of material sheets. Furthermore, even though the production management apparatus 110 receives the next schedule request from the controller 131 of the sheet metal factory processing installation 130 , the production management apparatus 110 does not respond to the schedule request without condition. More specifically, the production management apparatus 110 transmits the processing schedule of the next material sheet to the controller 131 at a timing (m minutes before processing end estimated time) when processing end estimated time of the preceding material sheet is synchronized with convey-in preparation completion estimated time of the next material sheet.

For this reason, the sheet metal factory processing system 101 can flexibly cope with an interrupt processing schedule generated at various timings and on various conditions. These various interrupt functions will be described below with reference to schematic layout diagrams shown in FIGS. 10 to 16 .

FIG. 10 shows a first example of the interrupt function of the sheet metal factory processing system 101 . In this example, when an interrupt processing schedule is generated in processing of the nth material sheet Sn (material and thickness M 1 ), if a timing of the generation is set before “m minutes before the processing end estimated time” of a material sheet Sn, the interrupt processing schedule can be executed regardless of the material and the thickness Mx, even though the interrupt processing schedule is one of the interrupt processing schedule A 1 .

In this manner, an automatic operation can be continued without stopping the sheet metal factory processing installation 130 including the #1 laser processing machine 136 .

FIG. 11 shows a second example of the interrupt function of the sheet metal factory processing system 101 . This example explains the following case. That is, when an interrupt processing schedule is generated in the duration of “m minutes before the processing end estimated time” of an nth material sheet Sn (material and thickness M 1 ), a material sheet A 1 used in the interrupt processing schedule has a material and a thickness M 1 which are the same as those of an (n+1)th material sheet Sn+1 (material and thickness M 1 ).

In this case, interrupt processing schedule data of the material sheet A 1 is dynamically nested in the material sheet Sn+1 to make it possible to execute an interrupt processing schedule of the material sheet A 1 by using the material sheet Sn+1.

In this manner, the automatic operation can be continued without stopping the sheet metal factory processing installation 130 including the #1 laser processing machine 136 .

FIG. 12 shows a third example of the interrupt function of the sheet metal factory processing system 101 . This example explains a case in which, when an interrupt processing schedule is generated in the duration of “m minutes before the processing end estimated time” of the nth material sheet Sn (material and thickness M 1 ), the material sheet A 1 used in the interrupt processing schedule has a material and a thickness M 2 which are different from those of the (n+1)th material sheet Sn+1 (material and thickness M 1 ).

In this case, the material sheet Sn+1 is in waiting in the loading/unloading shuttle 145 . By using the single-sheet pickup and conveying device 146 , the processed sheet (product) Sn is directly unloaded on the unloading buffer 144 . Subsequently, the material sheet A 1 is directly loaded from the loading buffer 143 to the #1 laser processing machine 136 by using the single-sheet pickup and conveying device 146 to make it possible to execute an interrupt processing schedule of the material sheet A 1 .

When a plurality of material sheets A 1 are used, the material sheets A 1 are sequentially subjected to the processing. In such an interrupt processing schedule, necessary re-nesting is performed first to cancel the processing schedule, which has been used, and a new processing schedule including an unprocessed part is formed.

Upon completion of the interrupt processing schedule, when the next schedule includes processing for a material sheet having the same material and thickness M 1 as those of the material sheet Sn+1, the material sheet Sn+1 being in waiting in the loading/unloading shuttle 145 is loaded on the #1 laser processing machine 136 to cause the #1 laser processing machine 136 to execute the processing.

In this manner, the automatic operation can be continued without stopping the sheet metal factory processing installation 130 including the #1 laser processing machine 136 .

FIG. 13 shows a fourth example of an interrupt function of the sheet metal factory processing system 101 . This example explains a case in which, when an nth material sheet Sn (material and thickness M 1 ) is loaded on the #1 laser processing machine 136 and waits for the start of processing, a special-express interrupt processing schedule A 1 (of material and thickness M 1 ) which can use the material sheet Sn is generated.

In this case, special-express interrupt processing schedule data is dynamically nested in the material sheet Sn to make it possible to execute the special-express interrupt processing schedule A 1 by using the material sheet Sn.

In this manner, the automatic operation can be continued without stopping the sheet metal factory processing installation 130 including the #1 laser processing machine 136 .

FIG. 14 shows a fifth example of the interrupt function of the sheet metal factory processing system 101 . This example explains a case in which, as shown in FIG. 15 , in processing of an nth material sheet Sn (material and thickness M 1 ), a forcible interrupt processing schedule A 1 (of material and thickness M 1 ) which can be reserved for a remaining material area of the material sheet Sn is generated.

In this case, forcible interrupt processing schedule data is dynamically nested in the remaining material area of the material sheet Sn to make it possible to execute the forcible interrupt processing schedule A 1 by using the remaining material area of the material sheet Sn.

In this manner, the automatic operation can be continued without stopping the sheet metal factory processing installation 130 including the #1 laser processing machine 136 .

FIG. 16 shows a sixth example of the interrupt function of the sheet metal factory processing system 101 . This example explains a case in which, as shown in FIG. 17 , in processing of a nth material sheet Sn (material and thickness M 1 ), a forcible interrupt processing schedule A 1 (of material and thickness M 1 ) which can be reserved for a unprocessed part area of the material sheet Sn is generated.

In this case, forcible interrupt processing schedule data is dynamically nested in the remaining material area of the material sheet Sn to make it possible to execute the forcible interrupt processing schedule A 1 by using the unprocessed part area of the material sheet Sn.

In this manner, the automatic operation can be continued without stopping the sheet metal factory processing installation 130 including the #1 laser processing machine 136 .

The explanation about the configurations, operations, and interrupt functions of the sheet metal factory processing system 101 is not limited to the sheet metal factory processing system 101 including only one sheet metal factory processing installation 130 as shown in FIG. 1 .

More specifically, for example, the explanation about the configurations, operations, and interrupt functions of the above described sheet metal factory processing system 101 can also be applied to a sheet metal factory processing system including a plurality of sheet metal factory processing installation cells each of which is configured by using the sheet metal factory processing installation such as the sheet metal factory processing installation 130 shown in FIG. 1 as a cell.

Furthermore, for example, the explanation about the configurations, operations, and interrupt functions of the above described sheet metal factory processing system 101 can also be applied to a sheet metal factory processing system in which one sheet metal factory processing installation has a plurality of processing machines and a plurality of peripheral devices.

In addition, the sheet metal factory processing installation cell is not limited to an installation, which receives a material from storage and stores a processed product in the storage. More specifically, for example, the explanation about the sheet metal factory processing system 101 can be basically applied to a sheet metal factory processing installation cell having an independent manipulator for conveying in/out a material in the cell or a sheet metal factory processing installation cell in which a material is manually conveyed in/our without a peripheral device by additionally arranging a controller 131 in the cell.

FIG. 18 is a schematic block diagram showing a second embodiment of the sheet metal factory processing system according to the invention. The sheet metal factory processing system 201 is formed by connecting a production management apparatus 210 and a plurality of sheet metal factory processing installations (sheet metal factory processing installation cells) 230 (# 1 to #n) to a network 220 .

The configuration of the production management apparatus 210 and the configuration of each sheet metal factory processing installations 230 are the same as those of the production management apparatus 110 and the sheet metal factory processing installation 130 in the sheet metal factory processing system 101 shown in FIG. 1 . Therefore, the same reference numerals as in FIG. 1 denote the same parts in FIG. 18 , and a detailed description thereof will be omitted such that a number 100 is added to the same reference numbers used in FIG. 1 each.

All the sheet metal factory processing installations 230 (# 1 to #n) are independently arranged. More specifically, the sheet metal factory processing installations 230 independently communicate with the production management apparatus 210 , cause controllers 231 to transmit schedule requests, and receive processing schedule from the production management apparatus 210 . The sheet metal factory processing installations 230 can perform sheet processing according to the processing schedule.

The production management apparatus 210 can independently communicate with the entire sheet metal factory processing installations 230 (# 1 to #n) and independently give processing schedules in response to the schedule requests from the sheet metal factory processing installations 230 to make it possible to execute the processing schedule.

However, since the production management apparatus 210 is connected to the plurality of sheet metal factory processing installations 230 (# 1 to #n), for example, when a fault occurs in processing one (#″) of the sheet metal factory processing installations 230 , a processing schedule to be performed in the sheet metal factory processing installation 230 (#″) can be executed in another sheet metal factory processing installation 230 (#″).

In this manner, a stop (waiting) time in the entire system can be shortened to make it possible to improve the operating rate and the production efficiency of the system.

The production management apparatus 210 can generate a manufacturing designation, which handles at least two sheet metal factory processing installations 230 as a group on the basis of production management. On the manufacturing designation, the production management apparatus 210 can generate a processing schedule which is reserved to the sheet metal factory processing installation groups 230 .

With respect to the processing schedule which is reserved for the sheet metal factory processing installation groups 230 , optimum scheduling is performed depending on the progress of the schedules of the sheet metal factory processing installations 230 in each group, so that a stop (waiting) time in each group is shortened to make it possible to improve the operating rate and the production efficiency of the system.

An operation of the embodiment will be described below with reference to flow charts shown in FIGS. 19 to 34 .

FIG. 19 shows a flow chart of a job controller 214 of the production management apparatus 210 . The job controller 214 is activated when the production management apparatus 210 is powered on. The job controller 214 always monitors a manufacturing arrangement and an interrupt arrangements from a production management unit 211 , schedule requests from the controllers 231 of the connected sheet metal factory processing installations 230 , and installation statuses of the sheet metal factory processing installations 230 .

As shown in FIG. 19 , the job controller 214 executes a new arrangement process (step S 1100 ) first.

Next, the job controller 214 executes a schedule forming process (Step S 1200 ).

The job controller 214 makes interrupt confirmation (step S 1001 ). Subsequently, the job controller 214 decides all the processes are finished (step S 1002 ). When all the processes are finished (YES in step S 1002 ), the flow is ended.

On the other hand, all the processes are not finished (No in step S 1002 ), the job controller 214 decides whether interrupt arrangement is set (step S 1003 ).

When the interrupt arrangement is set (YES in step S 1003 ), the job controller 214 executes an interrupt arrangement process (step S 1300 ). Thereafter, the job controller 214 returns to the “schedule forming process” in step S 1200 .

On the other hand, when the interrupt arrangement is not set (NO in step S 1003 ), the job controller 214 confirms the installation statuses of the sheet metal factory processing installations 230 (# 1 to #n) (step S 1004 ). Subsequently, the job controller 214 decides whether the sheet metal factory processing installations 230 are failed (step S 1005 ).

When the sheet metal factory processing installations 230 are failed (YES in step S 1005 ), the job controller 214 executes a schedule substituting process (step S 1400 ). Thereafter, the job controller 214 returns to the “schedule forming process” in step S 1200 .

On the other hand, when the sheet metal factory processing installations 230 are not failed (NO in step S 1005 ), the job controller 214 continuously decides whether the sheet metal factory processing installations 230 are recovered (step S 1006 ).

When the sheet metal factory processing installations 230 are recovered (YES in step S 1006 ), the job controller 214 executes a schedule reforming process (step S 1500 ). Thereafter, the job controller 214 returns to the “schedule forming process” in step S 1200 .

On the other hand, when the sheet metal factory processing installations 230 are not recovered (NO in step S 1006 ), the job controller 214 continuously decides whether the sheet metal factory processing installations 230 are overloaded (step S 1007 ).

When the sheet metal factory processing installations 230 are overloaded (YES in step S 1007 ), the job controller 214 executes the schedule reforming process (step S 1500 ). Thereafter, the job controller 214 returns to the “schedule forming process” in step S 1200 .

On the other hand, the sheet metal factory processing installations 230 are not overloaded (NO in step S 1007 ), the job controller 214 makes a schedule request confirmation (step S 1008 ). Subsequently, the job controller 214 decides whether a schedule request is made (step S 1009 ).

When the schedule request is made (YES in step S 1009 ), the job controller 214 executes a schedule transmitting process (step S 1600 ). Thereafter, the job controller 214 returns to the “interrupt confirmation” in step S 1001 .

On the other hand, when the schedule request is not made (NO in step S 1009 ), the job controller 214 continuously decides whether a halfway interrupt confirmation request is made (step S 1011 ).

When the halfway interrupt confirmation request is made (YES in step S 1011 ), the job controller 214 executes a halfway interrupt response process (step S 1700 ). Thereafter, the job controller 214 returns to the “interrupt confirmation” in step S 1001 .

On the other hand, when the halfway interrupt confirmation request is not made (NO in step S 1011 ), the job controller 214 returns to the interrupt confirmation in step S 1001 .

FIG. 20 is a flow chart of a new arrangement process (step S 1100 ) in the flow of the job controller 214 described above.

As shown in FIG. 20 , the new arrangement process forms a manufacturing arrangement (step S 1101 ) and stores the formed manufacturing arrangement.

FIG. 21 is a flow chart of a schedule forming process (step S 1200 ) in the flow of the job controller 214 described above.

As shown in FIG. 21 , in the schedule forming process, the job controller 214 reads one record of manufacturing arrangement (step S 1201 ).

In the schedule forming process, the job controller 214 reads the part data (step S 31202 ).

In the schedule forming process, the job controller 214 executes a processing possible/impossible decision process (step S 1210 ).

Subsequently, in the schedule forming process, in order to prevent only a specific sheet metal factory processing installation 230 from being overloaded by processing, job controller 214 adds manufacturing arrangement information to a nesting schedule of the sheet metal factory processing installation 230 which can be processed and has a minimum number of parts to be processed (step S 1203 ).

Subsequently, in the schedule forming process, the job controller 214 decides whether all the processes are finished (step S 1204 ). When all the processes are not finished (NO in step S 1204 ), the job controller 214 returns to the “reading of one record of manufacturing arrangement” in step S 1201 to repeat the processes until all the processes are finished.

On the other hand, when all the processes are finished (YES in step S 1204 ), in the schedule forming process, the job controller 214 specifies the next sheet metal factory processing installation (step S 1205 ).

In the schedule forming process, the job controller 214 executes a nesting process (step S 1220 ).

Subsequently, in the schedule forming process, the job controller 214 decides whether the processes in the entire sheet metal factory processing installations 230 (# 1 to #n) are finished (step S 1206 ). When the processes in all the sheet metal factory processing installations 230 (# 1 to #n) are not finished (NO in step S 1206 ), the job controller 214 returns to the “Specifying of next sheet metal factory processing installation” in step S 1205 to repeat the processes until the processes in all the sheet metal factory processing installations 230 (# 1 to #n) are finished.

On the other hand, all the sheet metal factory processing installations 230 (# 1 to #n) are finished (YES in step S 1206 ), the flow of the schedule forming process is ended.

FIG. 22 is a flow chart of a processing possible/impossible decision process (step S 1210 ) in the flow of the schedule forming process described above.

As shown in FIG. 22 , in the processing possible/impossible decision process, the job controller 214 reads information of an operable sheet metal factory processing installation (step S 1211 ).

Subsequently, in the processing possible/impossible decision process, the job controller 214 compares the thickness of a part with the maximum processing thickness (step S 1212 ). When the thickness of the part is larger than the maximum processing thickness (YES in step S 1212 ), in the processing possible/impossible decision process, the job controller 214 determines impossible processing and records the result (step S 1213 ).

On the other hand, when the thickness of the part is not larger than the maximum processing thickness (NO in step S 1212 ), the job controller 214 continuously compares a part size (X, Y) with the maximum processing range (step S 1214 ) in the processing possible/impossible decision process. When the part size is larger than the maximum processing range (YES in step S 1214 ), in the processing possible/impossible decision process, the job controller 214 determines impossible process and records the result (step S 1213 ).

On the other hand, when the part size is not larger than the maximum processing range (NO in step S 1214 ), in the processing possible/impossible decision process, the job controller 214 decides whether a tooling required to process the part is arranged (step S 1215 ). When the tooling required to process the part is not arranged (YES in step S 1215 ), in the processing possible/impossible decision process, the job controller 214 determines impossible processing and records the result (step S 1213 ).

On the other hand, when the tooling required to process the part is arranged (NO in step S 1215 ), in the processing possible/impossible decision process, the job controller 214 determines possible processing and records the result (step S 1216 ).

Subsequently, in the processing possible/impossible decision process, the job controller 214 decides whether the processes for the entire sheet metal factory processing installations are finished (step S 1217 ). When the processes for all the installations are nor finished (NO in step S 1217 ) the job controller 214 returns to the “reading of information of operable sheet metal factory processing installation” in step S 1211 to repeat the processes until the processes for all the installations are ended.

On the other hand, when the processes for all the installations are finished (YES in step S 1217 ), the flow of the processing possible/impossible decision process is ended.

FIG. 23 is a flow chart of a nesting process (step S 1220 ) in the flow of the schedule forming process described above.

As shown in FIG. 23 , in the nesting process, the job controller 214 reads a nesting schedule first (step S 1221 ).

In the nesting process, the job controller 214 reads an operation schedule (step S 1222 ).

In the nesting process, the job controller 214 adds an unprocessed part in the read operation schedule to the nesting schedule (step S 1223 ).

In the nesting process, the job controller 214 performs nesting (step S 1224 ).

In the nesting process, the job controller 214 calculates an estimated processing time (step S 1225 ).

Finally, in the nesting process, the job controller 214 updates the operation schedule (step S 1226 ).

FIG. 24 is a flow chart of an interrupt arrangement process (step S 1300 ) in the flow of the job controller 214 described above.

As shown in FIG. 24 , an the interrupt arrangement process, the job controller 214 executes an additional nesting process (step S 1310 ). The additional nesting process is shown in FIG. 25 .

As shown in FIG. 25 , in the additional nesting process, the job controller 214 acquires blank layout information of a sheet, which is being processed at present (step S 1311 ).

In the additional nesting process, the job controller 214 acquires interrupt part data (step S 1312 ).

In the additional nesting process, the job controller 214 performs additional nesting (step S 1313 ). The additional nesting includes the following operations. That is, for example, as shown in FIG. 15 , an arrangement position of an additional part is determined to perform blank layout of the part in a blank of a processed sheet and to process the part, and processing data is formed.

Subsequently, in the additional nesting process, the job controller 214 decides whether the additional nesting is succeeded (step S 1314 ). When the additional nesting is not succeeded (NO in step S 1314 ), the job controller 214 ends the additional nesting process.

On the other hand, when the additional nesting is succeeded (YES in step S 1314 ), in the additional nesting process, the job controller 214 selects a processing section as “addition” (step S 1315 ).

In the additional nesting process, the job controller 214 adds the corresponding part to an unprocessed forehead record (step S 1316 ).

In the additional nesting process, the job controller 214 stores the operation schedule (step S 1317 ). The job controller 214 ends the additional nesting process.

Returning to FIG. 24 , in the interrupt arrangement process, the job controller 214 decides whether the additional nesting process is possible (step S 1301 ).

When the additional nesting process is possible (YES in step S 1301 ), the interrupt arrangement process is ended.

On the other hand, when the additional nesting process is impossible (NO in step S 1301 ), in the interrupt arrangement process, the job controller 214 forms a manufacturing arrangement including only an interrupt part (step S 1302 ). The job controller 214 stores the formed manufacturing arrangement.

FIG. 26 is a flow chart of a schedule substituting process (step S 1400 ) in the flow of the job controller 214 described above.

As shown in FIG. 26 , in the schedule substituting process, the job controller 214 specifies a failed sheet metal factory processing installation (step S 1401 ).

In the schedule substituting process, the job controller 214 reads an operation schedule on the job controller 214 side (step S 1402 ).

In the schedule substituting process, the job controller 214 performs extraction of an unprocessed part and formation of a manufacturing arrangement (step S 1403 ). The job controller 214 stores the formed manufacturing arrangement.

FIG. 27 is a flow chart of a schedule reforming process (step S 1500 ) in the flow of the job controller 214 described above.

As shown in FIG. 27 , in the schedule reforming process, the job controller 214 specifies the next sheet metal factory processing installation (step S 1501 ).

In the schedule reforming process, the job controller 214 reads an operation schedule (step S 1502 ).

In the schedule reforming process, the job controller 214 adds an unprocessed part to the manufacturing arrangement (step S 1503 ).

In the schedule reforming process, the job controller 214 deletes the unprocessed part from the operation schedule (step S 1504 ).

Subsequently, in the schedule reforming process, the job controller 214 decides whether the processes for the entire sheet metal factory processing installations are finished (step S 1505 ). When the processes for all the sheet metal factory processing installations are not finished (NO in step S 1505 ), the job controller 214 returns to the “specifying of the next sheet metal factory processing installation” in step S 1501 to repeat the processes until the processes for all the sheet metal factory processing installations are finished.

On the other hand, the processes for the entire sheet metal factory processing installations are finished (YES in step S 1505 ), the schedule reforming process is ended.

FIG. 28 is a flow chart of a schedule transmitting process (step S 1600 ) in the flow of the job controller 214 described above.

As shown in FIG. 28 , in the schedule transmitting process, the job controller 214 acquires an operation schedule of the next sheet, which is being processed at present (step S 1601 ).

In the schedule transmitting process, the job controller 214 transmits data related to the acquired operation schedule to the controller 231 of the sheet metal factory processing installation cell 230 serving as a request source (step S 1602 ). In this case, the data related to the operation schedule includes arrangement data, processing data such as blank layout data, and an operation schedule.

In the schedule transmitting process, the job controller 214 changes the status into a status “transmitted” in the operation schedule and stores the status in the operation schedule (step S 1603 ).

FIG. 29 is a flow chart of a halfway interrupt response process (step S 1700 ) in the flow of the job controller 214 described above.

As shown in FIG. 29 , in the halfway interrupt response process, the job controller 214 acquires an operation schedule under processing (step S 1701 ).

Subsequently, in the halfway interrupt response process, the job controller 214 acquires an unprocessed forehead operation schedule (step S 1702 ).

In the halfway interrupt response process, the job controller 214 decides whether materials are matched with other (step S 1703 ). When the materials are not matched with each other (NO in step S 1703 ), the job controller 214 generates “no interrupt” as a response (step S 1704 ). The job controller 214 ends the halfway interrupt response process.

On the other hand, when the materials are matched with each other (YES in step S 1703 ) in the halfway interrupt response process, the job controller 214 replaces a forehead unprocessed operation schedule with a trailing transmitted operation schedule (step S 1705 ).

In the halfway interrupt response process, the job controller 214 changes the status of the replaced transmitted operation schedule into “unprocessed” (step S 1706 ).

In the halfway interrupt response process, the job controller 214 stores the operation schedule (step S 1707 ).

Subsequently, in the halfway interrupt response process, the job controller 214 decides whether the processing section of the replaced unprocessed operation schedule is additional processing (step S 1708 ). When the processing section is not the additional processing (NO in step S 1708 ), the job controller 214 generates a response as “interrupt processing to another sheet consisting of the same material” (step S 1709 ). The job controller 214 ends the halfway interrupt response process.

On the other hand, when the processing section is the additional processing (YES in step S 1708 ), the job controller 214 generates “interrupt processing to the same sheet” as a response (step S 1710 ). The job controller 214 ends the halfway interrupt response process.

FIG. 30 is a flow chart of the controller (cell controller) 231 of an arbitrary sheet metal factory processing installation (sheet metal factory processing installation cell) 230 .

The cell controller 231 always monitors a state of the sheet metal factory processing installation cell 230 according to the flow chart in FIG. 30 and activates a cell operation task for performing a cell operation process. For this reason, the cell operation task and the processes in the flow chart are simultaneously performed in parallel with each other (multitask operation).

As shown in FIG. 30 , the cell controller 231 sets an installation status of the sheet metal factory processing installation cell 230 as “prepared” (step S 3001 ).

The cell controller 231 sets the present time of the sheet metal factory processing installation cell 230 as schedule request time (step S 3002 ).

Subsequently, the cell controller 231 decides whether the processing schedule is ended with reference to internal information of the sheet metal factory processing installation cell 230 (step S 3003 ). When the processing schedule is ended (YES in step S 3003 ), the cell controller 231 updates the installation status of the sheet metal factory processing installation cell 230 (step S 3004 ) and ends the process.

On the other hand, when the processing schedule is not ended (NO in step S 3003 ), the cell controller 231 continuously decides whether the sheet metal factory processing installation cell 230 is over loaded with reference to the internal information of the sheet metal factory processing installation cell 230 (step S 3005 ). When the sheet metal factory processing installation cell 230 is overloaded (YES in step S 3005 ), the cell controller 231 updates the installation status of the sheet metal factory processing installation cell 230 (step S 3004 ) and ends the process.

On the other hand, when the sheet metal factory processing installation cell 230 is not overloaded (NO in step S 3005 ), the cell controller 231 continuously decides whether the sheet metal factory processing installation cell 230 is erroneous with reference to the internal information of the sheet metal factory processing installation cell 230 (step S 3006 ). When the sheet metal factory processing installation cell 230 is erroneous (YES in step S 3006 ), the cell controller 231 updates the installation status of the sheet metal factory processing installation cell 230 (step S 3004 ) and ends the process.

On the other hand, when the sheet metal factory processing installation cell 230 is not erroneous (NO in step S 3006 ), the cell controller 231 decides whether it is next schedule request time (step S 3007 ). When it is not the next schedule request time (NO in step S 3007 ), the cell controller 231 returns to the decision “whether the processing schedule is ended” in step S 3003 to repeat the processes.

On the other hand, when it is the next schedule request time (YES in step S 3007 ), the cell controller 231 activates a cell operation task (step S 3100 ).

FIG. 31 is a flow chart of the cell operation task (step S 3100 ) in the flow of the cell controller 231 described above.

As shown in FIG. 31 , in the cell operation task, the cell controller 231 executes a schedule request process (step S 3110 ).

In the cell operation task, the cell controller 231 decides whether there is a next schedule (step S 3121 ). When there is no next schedule (NO in step S 3121 ), the cell controller 231 ends the cell operation task.

On the other hand, when there is a next schedule (YES in step S 3121 ), in the cell operation task, the cell controller 231 performs a delivery process (S 3122 ).

Subsequently, in the cell operation task, the cell controller 231 decides whether the delivery process includes an error (step S 3123 ). When the delivery process includes an error (YES in step S 3123 ), in the cell operation task, the cell controller 231 performs an error process (step S 3124 ).

On the other hand, when the delivery process does not include error (NO in step S 3123 ), in the cell operation task, the cell controller 231 performs a loading process (step S 3125 ).

Subsequently, in the cell operation task, the cell controller 231 decides whether the loading process includes an error (step S 3126 ). When the loading process includes an error (YES in step S 3126 ), an the cell operation task, the cell controller 231 performs an error process (step S 3124 ).

On the other hand, when the loading process does not includes an error (NO in step S 3126 ), in the cell operation task, the cell controller 231 executes a same material halfway interrupt confirmation process (step S 3140 ).

In the cell operation task, the cell controller 231 performs a processing process (step S 3127 ).

In the cell operation task, the cell controller 231 decides whether the processing process includes an error (step S 3128 ). When the processing process includes an error (YES in step S 3128 ), in the cell operation task, the cell controller 231 performs an error process (step S 3124 ).

On the other hand, when the processing process does not include an error (NO in step S 3128 ), in the cell operation task, the cell controller 231 executes the same sheet halfway interrupt confirmation process (step S 3150 ).

In the cell operation task, the cell controller 231 performs an unloading process (step S 3129 ).

Subsequently, in the cell operation task, the cell controller 231 decides whether the unloading process includes an error (step S 3131 ). When the unloading process includes an error (YES in step S 3131 ), the cell operation task performs an error process (step S 3124 ).

On the other hand, when the unloading process does not include an error (NO in step S 3131 ), in the cell operation task, the cell controller 231 executes an end process (step S 3160 ). This end process (step S 3160 ) will be described later.

FIG. 32 is a flow chart of a schedule request process (step S 3110 ) in the flow of the cell operation task described above.

As shown in FIG. 32 , in the schedule request process, the cell controller 231 requests a schedule to the job controller 214 (step S 3111 ).

In the schedule request process, when the cell controller 231 receives the schedule from the job controller 214 (step S 3112 ), the cell controller 231 stores an operation schedule of one record and a processing schedule of one record.

Subsequently, in the schedule request process, the cell controller 231 decides whether there is a next schedule (step S 3113 ). When there is no next schedule (NO in step S 3113 ), the cell controller 231 ends the schedule request process.

On the other hand, when there is a next schedule (YES in step S 3113 ), in the schedule request process, the cell controller 231 reads an operation schedule and processing time (step S 3114 ).

In the schedule request process, the cell controller 231 reads delivery time and loading time (step S 3115 ).

In the schedule request process, the cell controller 231 acquires present time (step S 3116 ).

In the schedule request process, the cell controller 231 sets next schedule request time (step S 3117 ).

FIG. 33 is a flow chart of a halfway interrupt confirmation process (steps S 3140 and S 3150 ) in the flow of the cell operation task described above.

As shown in FIG. 33 , in the halfway interrupt confirmation process, the cell controller 231 requests the job controller 214 to perform halfway interrupt confirmation (step S 3141 ).

In the halfway interrupt confirmation process, the cell controller 231 receives halfway interrupt confirmation result from the job controller 214 (S 3142 ).

Subsequently, in the halfway interrupt confirmation process, the cell controller 231 decides whether there is interrupt processing (step S 3143 ). When there is no interrupt processing (NO in step S 3143 ) corresponding to the “no-interrupt” response (step S 1704 ) of the halfway interrupt response process in FIG. 29 , the cell controller 231 ends the halfway interrupt confirmation process.

On the other hand, when there is interrupt processing (YES in step S 3143 ) corresponding to the “interrupt processing to another sheet consisting of the same material” (step S 1709 ) of the halfway interrupt response process in FIG. 29 or the “interrupt processing to the same sheet” response (step S 1710 ), in the halfway interrupt confirmation process, the cell controller 231 executes an end process (step S 3160 ).

The end process (step S 3160 ) will be described below. FIG. 34 is a flow chart of the end process (step S 3160 ).

As shown in FIG. 34 , in the end process, the cell controller 231 decides whether processing is completed (step S 3161 ). More specifically, when the response of the halfway interrupts response process is “interrupt processing to another sheet consisting of the same material” (step S 1709 ), the corresponding sheet is not processed (YES in step S 3161 ). For this reason, in the end process, the cell controller 231 cancels the last processing schedule (step S 3162 ).

On the other hand, when the response of the halfway interrupts response process is “interrupt processing to the same sheet” (step S 1710 ), the corresponding sheet has been partially processed (NO in step S 3161 ), in the end process, the cell controller 231 updates the last processing actual results (step S 3163 ).

An end process (step S 3160 ) in the flow of the cell operation task in FIG. 31 is the same as described above. More specifically, in the end process under the same material halfway interrupt confirmation process (step S 3140 ), another sheet consisting of the same material is not processed (YES in step S 3161 ). For this reason, the cell controller 231 cancels the last processing schedule (step S 3162 ).

On the other hand, in the end process under the sane sheet halfway interrupt confirmation process (step S 3150 ), since the corresponding sheet has been partially processed (NO in step S 3161 ), the cell controller 231 updates the last processing actual results (step S 3163 ).

In this manner, although the “same material halfway interrupt confirmation process” shown as step S 3140 in FIG. 31 and the “same sheet halfway interrupt confirmation process” shown as step S 3150 in FIG. 31 are differently named for descriptive convenience, both the processes mean the “halfway interrupt confirmation process” shown in FIG. 33 each.

Here, in the end process (step S 3160 ) at the end of the flow in FIG. 31 , the cell controller 231 updates the actual results (step S 3163 ) of the processing process (step S 3127 ).

Returning to FIG. 33 , in the halfway interrupt confirmation process, the cell controller 231 requests a schedule to the job controller 214 (step S 3144 ).

In the halfway interrupt confirmation process, when the cell controller 231 receives a schedule from the job controller 214 (step S 3145 ), the cell controller 231 stores an operation schedule of one record and a processing schedule of one record.

In the halfway interrupt confirmation process, the cell controller 231 reads the operation schedule and the processing time (step S 3146 ).

In the halfway interrupt confirmation process, the cell controller 231 acquires present time (step S 3147 ).

Finally, in the halfway interrupt confirmation process, the cell controller 231 sets next schedule request time (step S 3148 ).

FIG. 35 is a schematic block diagram showing a third embodiment of the sheet metal factory processing system according to the invention. In a sheet metal factory processing system 301 , two sheet metal factory processing installations 330 (# 1 and # 2 ) share a controller 331 , a line control box 337 , and a peripheral device 340 . The controller 331 is connected to a production management apparatus 310 through a network 320 .

The configuration of the production management apparatus 310 and the configuration of the sheet metal factory processing installations (sheet metal factory processing installation cells) 330 are substantially the same as those in the sheet metal factory processing system 101 shown in FIG. 1 . For this reason, the same reference numerals as in FIG. 1 denote the same parts in FIG. 35 , and a detailed description thereof will be omitted such that a number 200 is added to the same reference numerals used in FIG. 1 each. Only the peripheral device 340 will be described below with reference to FIG. 36 .

FIG. 36 is a schematic diagram showing an arrangement of the peripheral device 340 in the sheet metal factory processing system 301 . The peripheral device 340 includes a material storage 341 , a product storage 342 , a loading buffer 343 , an unloading buffer 344 , two loading/unloading shuttles 345 (# 1 and # 1 ), and a single-sheet pickup and conveying device 346 which are arranged around two processing machines 336 (# 1 and # 2 ).

In the sheet metal factory processing system 301 , the two sheet metal factory processing installations 330 (# 1 and # 2 ) are constituted as an integrated unit from the first. For this reason, a processing schedule is handled as sheet metal factory processing installation units 330 (# 1 and # 2 ), so that precise optimum scheduling can be performed.

In this manner, a stop (waiting) time of the unit can be shortened. Therefore, a stop (waiting) time of the entire system is shortened to make it possible to improve the operating rate and the production efficiency of the entire system.

FIG. 37 is a schematic block diagram showing a fourth embodiment of the sheet metal factory processing system according to the invention. In the sheet metal factory processing system 401 , a production management apparatus 410 , a plurality of sheet metal factory processing installations (sheet metal factory processing installation cells) 430 (# 1 to #n), and a automatic warehouse installation 450 are connected to the network 420 .

The configuration of the production management apparatus 410 and the configuration of the sheet metal factory processing installations 430 are substantially the same as those in the sheet metal factory processing system 101 shown in FIG. 1 . For this reason, the same reference numerals as in FIG. 1 denote the same parts in FIG. 37 , and a detailed description thereof will be omitted such that a number 300 is added to the same reference numerals used in FIG. 1 each.

The automatic warehouse installation 450 includes an automatic warehouse controller 451 , an automatic warehouse control box 452 , and a material/product automatic warehouse/storage installation 453 . In the automatic warehouse installation 450 , the automatic warehouse controller 451 is connected to the network 420 .

The automatic warehouse controller 451 exchanges various data with a job controller 414 of the production management apparatus 410 through the network 420 , and also exchanges various necessary data with the components of the automatic warehouse installation 450 .

The automatic warehouse control box 452 is connected to line control boxes 437 of the plurality of the sheet metal factory processing installations 430 (# 1 to #n). The automatic warehouse control box 452 controls delivery and storage of a material/product in cooperation with peripheral devices 440 in the sheet metal factory processing installations 430 (# 1 to #n).

The material/product automatic warehouse/storage installation 453 , as shown in FIG. 38 , is combined to processing machine cells 436 including the peripheral devices 440 of the sheet metal factory processing installations 430 (# 1 to #n). The material/product automatic warehouse/storage installation 453 delivers and supplies necessary material sheets to all the processing machine cells 436 (# 1 to #n) and receives processed sheets (products) from the processing machine cells 436 (# 1 to #n) to store the processed sheets.

In the sheet metal factory processing system 401 , as in the sheet metal factory processing system 201 shown in FIG. 18 , optimum scheduling is performed to the processing schedules of the plurality of sheet metal factory processing installations 430 (# 1 to #n), so that a stop (waiting) lime of the entire system is shortened to make it possible to improve the operating rate and the production efficiency of the system.

Although the invention has been described above by reference to certain embodiments of the invention, the invention is not limited to the embodiments described above. Modifications and variations of the embodiments described above will occur to those skilled in the art, in light of the above teachings. The scope of the invention is defined in the following claims.