CN112955834A - Automated production process and production system for bending glass sheets with integrated digital imaging - Google Patents

Abstract

The invention relates to an automated production process for curved plates, in which a plate can be processed by means of a movable system component, wherein the movable system component can be controlled by a programmable logic controller on the basis of manually input parameter values, wherein the programmable logic controller can output control signals to actuators of the movable system component and can receive sensor signals of sensors for detecting the actual state of the actuators, wherein the manually input parameter values for controlling the movable system component are transmitted to a digital image of the automated production process, a collision of the system component due to a movement of at least one movable system component is checked, wherein in the event of a collision, a forwarding of a control signal based on the parameter values by the programmable logic controller to the actuator is prevented And the actuator or the control signal based on the parameter value is output to the actuator by the programmable logic control device under the condition that no collision occurs.

Description

Automated production process and production system for bending glass sheets with integrated digital imaging

Technical Field

The present invention is in the technical field of glass sheet manufacturing and relates to an automated production process for bending glass sheets with integrated digital imaging of the production process. In addition, the invention also relates to an automated production system for carrying out the automated production process for bending glass sheets according to the invention.

Background

In the production of glass panes for motor vehicles, flat glass is cut, pre-processed and then subjected to a glass bending process at elevated temperatures in the range from 500 ℃ to 750 ℃ in order to build up the arching geometry typical for motor vehicles. Especially in the field of glazing passenger vehicles, passenger safety is of great importance. Since untreated glass carries a serious risk of injury in the event of a break, single-ply safety glass is mainly installed as windshields, rear windows or side windows. Single-ply safety glass is made of ordinary glass by a hot-pretensioning process consisting of heating and subsequent rapid cooling. The internal stress thus introduced increases the fracture strength. At the same time, it ensures that the glass breaks apart at the break into small pieces with blunt edges. The bending and the thermal pretensioning of the plates are usually carried out in a combined production process in which the plates are heated to a bending temperature for the thermal pretensioning.

In WO 2004/087590 and WO 2006072721, respectively, a method is described in which the sheet is first pre-bent by gravity on a bending frame and then press-bent by means of an upper or lower bending die. Bending the sheet by suction against the upper bending mould is described in EP 255422 and US 5906668, respectively. From EP 1550639 a1, US 2009/084138 a1 and EP 2233444 a1, respectively, an apparatus is available in which the press frame on a slide can be transported between bending stations, the slide being movably supported on a stationary carrier.

DE 102005043022 a1 shows a method for controlling and/or monitoring the movement of a free body in an industrial machine, wherein the movement of the free body is simulated.

In the industrial mass production of glass sheets, automated production systems are used in which the movement of movable system components is regulated by means of actuators (e.g. electric motors) and sensors. For example, a servomotor, which is composed of an electric motor and a sensor, in conjunction with a motor controller, can be moved to a fixedly defined position. Sensors (encoders), such as rotary encoders, detect the actual states of the actuators and encode these actual states into digital signals.

The actuator typically has a separate controller (e.g., a motor controller). However, the movement controller of the actuator is usually controlled by at least one higher-order programmable logic control device (SPS). This programmable logic control contains the control logic for the flow of the entire production process and aggregates all process data at the central point. The SPS coordinates the production process by transmitting the nominal values to the downstream motion controllers at the correct points in time and by feeding back the sensor values in the process to monitor the process flow. SPS is therefore the central control mechanism for automated production processes.

In this case, it is important that the human operator be able to influence the automated process flow via a human-machine interface (MMS) by entering specific control variables (parameter values) for controlling the production process. For this purpose, the production process is parameterized. By changing the values of the process parameters, the programming of the SPS is not changed. In this case, the operator has an important task, since it is often necessary to change the parameter values in the automated production process if the process conditions have changed. For example, if the tool is replaced or if in general a further method with a reduced cycle time, which is optimized, for example, in terms of time, is to be carried out, the actuator needs to be actuated in a different manner. This requires a trained operator and is challenging, since modern systems for automated glass bending become more and more complex due to additional functions.

It is particularly important in the case of changing process parameters to maintain machine safety, wherein collisions of system components must be avoided in any case. Collisions can cause damage to system components and can result in long down-time of the production system. However, as the complexity of automated production systems continues to increase, it is sometimes difficult to set the parameters such that machine safety is always present.

Even worse, the bending of the glass sheets is carried out in a hot environment, the spatial accessibility of which is limited, making it difficult and completely impossible to visually monitor the production process in a determined viewing position or viewing angle. It is sometimes difficult or impossible for an operator to identify whether a system component is dangerously close.

Furthermore, it is important for the practice of mass production that the cycle time is short. The task the operator is responsible for here is to reduce the distance of the movable system components by entering optimized parameter values, to increase the speed and acceleration of the movable system components if necessary, and to ensure a rapid sequential access to the glass sheets to be processed in order to achieve a time reduction of the production process in general. However, this increases the risk of collision of the system components that can move.

However, in practice it always occurs that the operator inputs parameter values which lead to a collision of system components. This should be avoided anyway.

Disclosure of Invention

In contrast, the object of the present invention is to provide an improved automated production process for curved plates and an automated production system with which these disadvantages can be avoided. The operator should therefore be able to use, in particular, changing parameter values without risking a collision of movable system components in this case. Furthermore, the parameter values should be able to be optimized without risk with regard to the process properties that can be selected, preferably without risk with regard to the cycle time for processing the plate. Generally, the operator should always ensure machine safety when changing parameters.

These and other tasks are solved according to the present invention by an automated production process for curved sheets and an automated production system for carrying out the method according to the appended claims. Advantageous embodiments of the invention result from the dependent claims.

According to the invention, an automated production process for curved plates is shown, in which a plate can be processed by means of a movable system component, wherein the movable system component can be controlled by a programmable logic control device (SPS) on the basis of manually input parameter values. The programmable logic control device can output a control signal to an actuator of the movable system component and can receive a sensor signal of a sensor for detecting an actual state of the actuator.

According to the invention, in the automated production process, parameter values manually input by an operator for controlling the movable system components are transmitted to a digital image of the automated production process. The system components are then checked for a collision due to the movement of at least one movable system component, wherein in the event of a collision, a control signal based on the parameter value is prevented from being forwarded by the programmable logic control device to the actuator, or in the event of no collision, a control signal based on the parameter value is output by the programmable logic control device to the actuator. Thus, upon recognition of a collision of a system component, the machine control is automatically intervened by preventing the transmission of the control signal to the actuator. On the other hand, if no collision is identified, such blocking of the control signal is not performed. Thus, the production system is reliably and safely protected from collisions with system components.

In the sense of the present description, a "movable system component" is understood to mean a system component which is held on a forced movement path by an actuator, in contrast to a free body, for example a plate. Unlike movable system components, the robot cannot be held on a forced movement path only by an actuator. Correspondingly, the plate is not a movable system component in the sense of the present invention.

The invention is based on the following recognition: an integrated digital map (also referred to as "digital shadow") of an automated production process for curved plates can be advantageously used in a real production process. In particular, the problems mentioned at the outset in automated bending processes, which are described in more detail below, can be avoided thereby. The digital image simulates the actual production process in a procedural implementation (software) which is implemented in a set of logic structures that are already present or are additionally provided for this purpose.

Digital mapping of automated production processes requires automatic, computer-assisted processing of process data, in particular control data and sensor data. In order to be able to present these data in digitized form and also to be able to be influenced, it is necessary to use a programmable logic control device (SPS). The automated production process is controlled by an operator by manually entering specific control variables (parameter values).

The digital image comprises a three-dimensional (3D) simulation of the kinematics of the system components of the production system that can be moved (by means of the respective actuators on the forced movement path), in particular of the entire production system, and optionally a kinematic visualization of the simulation of the at least one system component that can be moved on the at least one monitor. The upper-level control of the kinematics simulation is performed by an SPS, which can be implemented in hardware or software (simulation). Communication and data means are also provided which enable bidirectional communication by means of preferably standardized machine-to-machine (M2M) communication, so that the current process data are accessed at a sufficient update rate. Preferably, the communication and data means are also capable of storing process data. As an interface to the real process, the communication and data device is directly connected to the SPS of the real production process. The kinematic simulation obtains the required process data from the communication and data device and is additionally connected to the digitally mapped SPS.

The numerical map maps the behavior and performance of the automated production process with a degree of refinement that matches its application purpose of assisting human operators in the process run. The aim is to acquire past, present and/or future knowledge about automated production processes, wherein the future production processes are essentially emphasized in the framework of the present description. This acquired knowledge is used to assist the operator in his task as a process leader and the highest level decision-making mechanism.

An important component of digital imaging is the kinematic simulation of automated production processes. First, a geometric model of the production system, in which the production process to be mapped takes place, is built for this purpose within the kinematic simulation model. The degree of refinement is at the discretion of the modeler and must be adapted to the goals of the digital map and the specific production process. On the one hand, therefore, it can be expedient to even refine a single screw when it is, for example, to limit the movement of further system components or is otherwise important for the course of the production process. On the other hand, in other scenarios, even larger, complex components may be replaced by placeholder geometries or omitted entirely. Preferably, a digital 3D geometric model is created using a Computer Aided Design (CAD) system, which is typically built as an edge model, a face model or a volume model. After the geometric model of the production system, the second element simulated is the kinematic model. The kinematic model is associated with the geometric model that does not move initially and therefore allows to mimic all the kinematic degrees of freedom of a real production process. Advantageously, the influence of the actual actuator on the production process is simulated in a simplified manner by the kinematic constraints. For example, a table is observed, which is connected to a motor via a spindle and can therefore be moved linearly uniaxially in a guide. The electric motors are controlled by a motor controller which receives as parameters nominal values for the axis position, speed and acceleration of the table. In the simulation model, the 3D geometry model of the table is advantageously assigned a single-axis linear degree of freedom, so that its position can be directly influenced by the variables. This simplification largely departs from the original mechanical behavior, but nevertheless allows the flow of the production process to be reproduced accurately. Another component of the kinematic simulation is the sensing mechanism. In a real production process, the controller (SPS) requires sensor data of the process as input values, so that this controller can specify nominal values for the actuators as a reaction to the input values. Correspondingly, these sensor data must be simulated by a simulation model. Through 3D kinematic simulations, the process flow is mapped by the kinematic behavior of the production system affected by the actuators. The primary state variable is the position variable of the movable system component. Optionally, a glass sheet is incorporated into the process flow.

Due to the external parameterizability of the SPS control program, it is possible to simulate any parameter configuration and its influence on the process flow. First, it is important information for the process operator whether the control program is functioning properly, using the selected parameter values. Problems associated with this can be whether all positions can be reached at a given speed, whether the glass sheet is successfully transported, or whether a collision occurs. In addition to this, the influence on process parameters (e.g. the cycle) is important. It is particularly advantageous to visualize the simulated process flow by means of 3D animation on at least one monitor, which enables information of the flow of a complex production process to be transferred to a person more efficiently with a new parameterization than merely text-based information.

In the automatic production process, the SPS controls the process and the motion flow. The sensor is attached to the input of the SPS and the actuator is attached to the output. The use of digital maps to show future process states requires that the future process states be simulated independently of the actual process. Therefore, the 3D kinematic simulation must be controlled separately, similar to the working principle of SPS. The most important objective here is the transferability of the simulation results to the controller of the real process. Ideally, the same parameter configuration leads to the same motion flow, whether the SPS used in the process, another SPS in the hardware, or a mapping (simulation) of the SPS is used for the kinematic simulation. Furthermore, the control within the simulation also allows a complete decoupling of the sensor means within the simulation model, since the control program has direct access to all simulated process states and process variables. For example, SPS simulation is connected with 3D kinematic simulation. Since real control programs are used in the SPS simulation, all sensors of the automated production process required for the motion control are required to be implemented in the simulation model, and the sensor signals need to be present in an SPS-compatible form. Furthermore, sensors and actuators for 3D kinematic simulation need to be coupled to virtual inputs or outputs of the SPS simulation.

Particularly advantageously, the digital map can thus generate information about the state of the future process or the state of the production system by means of kinematic simulation. By means of kinematic simulation, the flow of the production process can be shown independently of the current process data of the actual process being carried out. Thereby enabling the digital map to account for the effect of parameter changes on any process parameter. Based on this, suitable optimization strategies can be used for optimizing the process parameters in terms of the determined criteria. In particular, collisions of system components can be avoided.

It is also possible that the digital map uses process data of the actual production process in operation and is therefore constantly in the same state as the actual process. Based on these data, the digital map is able to visualize the current state of the production system by means of a schematic (e.g. 3D animation) on at least one monitor. In addition, this data stream can be used for process analysis purposes. Thus, new process-related variables can be generated from the existing data by aggregation, reduction or calculation and can be visualized correspondingly. In this case, the digital map can also perform a security check by monitoring the security-relevant process variables and comparing them with the previously defined rules.

It is also contemplated that by processing earlier process data, the digital map can analyze and show the cause of the fault.

The results of the digital image are transmitted to the operator visually and if necessary on a text basis by way of a visual representation on at least one monitor. Text-based information can also be displayed by MMS, for example.

The communication and data device determines which data are not only processed but also stored in which form and passes these data to the 3D kinematics simulation as required. The required process data of the real process are read out by a connection to the SPS, which processes these process data centrally. The main task of the communication and data device is therefore to transmit historical and current process data to the simulation in a compatible data format and at a sufficient update rate.

Operator interaction with the digital map can occur substantially at three different levels. First of all, a digital map can implement a purely informative function, i.e. this digital map provides a person with information which the person must interpret independently and which, if necessary, can be implemented in a process intervention. The information can either be requested manually by the operator or can be provided automatically by the digital image. In the method according to the invention, the process flow based on previously entered parameter values is visually shown on at least one monitor.

The second stage is to propose processing recommendations via the digital image that can either be accepted or rejected by the user. The advice can also be triggered either manually by a person or automatically.

The third phase describes a fully automated process by digital imaging which places the operator in a passive position. This operator monitors the actions performed automatically and can decide to react to these actions by himself. However, the operator is the highest level decision mechanism and manually decides which information is actually to be fed back into the real process.

As described above, according to the invention, it is proposed that, based on manually entered parameter values, information about the future process state or the state of the production system is generated by means of a kinematic simulation of the movable system component, and, in the event of a collision of the system component, which is caused by the movement of at least one system component, transmission of a control signal based on the entered parameter values to the actuator is prevented. Thus, the operator can input new parameter values without danger. The machine safety of the production system is always ensured. The transmission of the control signal based on the parameter value to the actuator can be prevented in the programmable logic control. However, it is also possible to prevent a control signal based on the parameter value from being forwarded to the actuator in an actuator control device (for example a motor controller) controlled by a programmable logic control device.

According to an advantageous embodiment of the automated production process for curved panels, in the event of a collision, corresponding information or messages are output on at least one monitor. Preferably, the colliding system components are shown on at least one monitor in sharp contrast in color to the non-colliding system components. It is also possible, for example, to stop the simulated process flow if a collision of a system component occurs. Since the kinematic simulation has the geometry of the system components, such a collision check can be implemented in a simple manner, wherein it is only necessary to test whether the external dimensions of the system components overlap or overlap.

According to a further advantageous embodiment of the automated production process for curved panels, a simulated movement sequence of the movable system components is shown on the at least one monitor in an enlarged representation and/or in different perspectives in the event of a collision. This enables the operator to perform accurate visual identification of the process flow, which is not typically possible due to the particularities of the thermal bend zones in real production systems. It is particularly advantageous to show a simulated movement sequence of the movable system component on the at least one monitor from an externally inaccessible point of view.

According to a further advantageous embodiment of the automated production process for curved panels, a simulated movement sequence of the movable system component is shown on the at least one monitor after a time delay in the event of a collision. This enables the operator to study the simulated process flow very accurately-as if in a slow shot.

According to a further advantageous embodiment of the automated production process for curved panels, in the event of a collision, in addition to the visual representation of the movement sequence of the movable system component, further information is shown on the at least one monitor, which can be useful to the operator. Preferably, at least one displacement time diagram (cycle diagram) of at least one movable system component is shown on at least one monitor. This facilitates the operator to analyze the process flow.

The automated production method for curved panels, recovered in a digital image, preferably comprises the following (e.g. successive) steps:

a plate heated to a bending temperature is provided in the bending zone, for example directly below the mould. The plate is fixed at the contact surface (of the tool) of the mould. Advantageously, the plates are fixed by blowing a gaseous fluid towards the plates. Alternatively, and preferably additionally, the plates are fixed at the contact surfaces of the mould by suction. The frame is positioned in the bending zone, for example directly below the mould, while the plate is fixed at the mould and the plate is placed on the frame. The frame is used to transport the plates in a resting manner, wherein the plates can be bent by gravity.

Optionally, a pressing frame is provided within the bending zone, wherein the plate is pressed between the die and the pressing frame. Alternatively, the tray can be placed on the pressing frame.

Optionally, a pretensioning frame is provided in the bending zone, wherein the plates are transported on the pretensioning frame to a cooling device for thermally pretensioning the plates. During transport on the pre-tensioned frame, the panel can be bent in its inner region by gravity.

For example, a press frame is first provided in the bending zone, then the plate is pressed between the die and the press frame, then a pretension frame is provided in the bending zone, and the plate is placed on the pretension frame.

It is obvious that, in order to produce complex geometries, the plates can be fixed at a plurality of moulds one after the other in time.

Preferably, at least one mould is moved translationally up and down only in the vertical direction. Preferably, the at least one frame is reciprocated translationally only in the horizontal direction.

The invention further relates to an automated production system for curved sheets, which is suitable for carrying out the method according to the invention. The production system comprises a movable system component for processing the plate, which can be controlled by a programmable logic control device based on a manually input parameter value. The programmable logic control device can output a control signal to an actuator of the movable system component and can receive a sensor signal of a sensor for detecting an actual state of the actuator. The production system has a digital image of the automated production process and at least one monitor for showing content relating to the process flow. The production system is programmed in such a way that manually entered parameter values for controlling the movement of the movable system component are transmitted to a digital image of the automated production process, and a collision of the system component due to the movement of at least one movable system component is checked, wherein in the event of a collision, a control signal based on the parameter values is prevented from being forwarded by the programmable logic control device to the actuator, or in the event of no collision, a control signal based on the parameter values is output by the programmable logic control device to the actuator.

Within the framework of the present invention, the term "sheet" refers generally to a glass sheet, for example soda-lime glass.

Advantageously, the automated production system for curved panels comprises a plurality of zones that can be differentiated from each other in terms of structure and function. The bending zone for bending the hot plate, which is advantageously equipped with heating means for heating the plate, is an important component. In particular, for this purpose, the bending zone can be brought to a temperature at which plastic deformation of the plate can be achieved, for example in the range from 500 ℃ to 750 ℃. The bending zone is preferably designed as a closed or closable, heatable chamber facing the outside environment.

For bending the plate, the bending zone comprises at least one mould, which can be equipped with tools for fixing the plate, and at least one frame (e.g. a ring-shaped frame) on which the plate can be laid down. Typically, the board lies flat on the frame with only the board edges. The tool has a contact surface for contacting the plate. The contact surfaces are configured in a suitable manner for bending the plate in the desired manner. The frame serves for laying the plate and, if appropriate, for pressing the edge region of the plate with the die. In the form of a pressing frame, the frame has a pressing face configured to complement a contact face of a tool of the die. Advantageously, the frame is configured in a suitable manner for the planar pre-bending by gravity in an inner region of the plate, wherein the inner region of the plate can sag downward by gravity. For this purpose, the frame can be open, i.e. provided with a central perforation, but can also be completely flat, as long as the sagging of the inner region of the plate can be achieved. The open design is preferred in view of simpler handling (processierung) of the plate.

In one embodiment, the bending zone has at least one die and a press frame assigned to the at least one die, wherein the die and the press frame can be vertically offset relative to one another, so that the plate can be pressed between the die and the press frame in the edge region. Preferably, the mold can be moved in the vertical direction only in translation (one-dimensionally or uniaxial). Preferably, the press frame is movable in a horizontal plane only in translation. This enables simple control of the die and the press frame. For example, the bending zone has only a single die and an associated press frame. For more complex plate geometries, the bending zone can also have, for example, two or more dies and at least one associated press frame, wherein the plate is bent in a plurality of stages.

Preferably, at least one of the moulds has means for fixing the plate at its contact surface, for example a pneumatic suction device for sucking a gaseous fluid, in particular air, by means of which the plate can be pulled towards the contact surface by means of underpressure. For this purpose, the contact surface can be provided, for example, with at least one suction opening, advantageously with a plurality of suction openings distributed, for example, uniformly over the contact surface, at which suction openings a vacuum can be applied in each case for the suction effect at the contact surface. The suction device generates a generally upwardly directed flow of a gaseous fluid, in particular air, which is sufficient to fix the plate at the contact surface. This makes it possible, in particular, to place a frame for receiving a plate fixed at the contact face below the plate. Alternatively or additionally, the means for fixing the plate at the contact surface comprise a pneumatic blowing device for generating a gaseous fluid flow, in particular an air flow, which is configured such that the gaseous fluid flow can blow from below towards the plate, thereby lifting the plate and pressing the plate towards the contact surface of the mold. The fixing of the plate at the contact surface of the mould is not necessarily accompanied by a bending process, but can lead to bending of the plate.

Advantageously, the automated production system has a preheating zone with a heating device for heating the plate to the bending temperature, and a transport mechanism, in particular of the roller bed type, for transporting the plate from the preheating zone to the bending zone, in particular to a removal position (for example directly) below the mould. Advantageously, the roller bed is configured such that the individual plates can be transported in succession to the removal position. The removal position can correspond in particular to an end section of the roller bed.

Advantageously, the automated production system additionally has a hot preloading region with a cooling device for the hot preloading plates, wherein a preloading frame (preloading ring) can be provided for transporting the plates from the bending region into the preloading region. By means of the hot pretensioning (annealing), a temperature difference is produced in a targeted manner between the surface region and the core region of the plate in order to increase the fracture strength of the plate. The prestressing of the plates is advantageously produced by means of a device for blowing a gaseous fluid, preferably air, towards the plates. Preferably, both surfaces of the plate are simultaneously loaded with air streams for cooling.

For example, the production system has at least one mold, a pressing frame (e.g. a pressing ring) and a pretensioning frame (pretensioning ring), wherein the mold can be lowered and raised by a reciprocating (reziprok) translational movement in the vertical direction, and both the pressing frame and the pretensioning frame can be respectively displaced by a reciprocating (reziprok) translational movement in the horizontal direction, in particular into a position directly below the at least one mold. The die can thus receive the plate, press it with co-action with the press frame, and then the plate is lowered on the pretensioning frame. In this case, the pressing frame and the pretensioning frame can advantageously be moved in succession into a position directly below the die.

The different embodiments of the invention can be implemented individually or in any combination. In particular, the features mentioned above and those yet to be explained below can be used not only in the respectively specified combination, but also in other combinations or alone without departing from the framework of the invention.

Drawings

The invention will be elucidated in detail below on the basis of embodiments, wherein reference is made to the appended drawing. Shown in a simplified, not to scale schematic diagram:

FIG. 1 is a schematic view of an exemplary automated production process for curved sheets;

FIG. 2 is a top view of a production system for curved sheets for use in the production process of FIG. 1;

FIG. 3 is a schematic illustration of process control by SPS;

FIG. 4 is a diagram illustrating information flow in the production system of FIG. 2;

FIG. 5 is a diagram illustrating information flow in the production system of FIG. 2 with an integrated digital image;

FIG. 6 is a chart for illustrating information flow in the case of a first application of a digital image in the production system of FIG. 5;

FIG. 7 is a chart for illustrating information flow in a second application case of the digital image in the production system of FIG. 5;

FIG. 8 is a chart for illustrating information flow in the case of a third application of digital images in the production system of FIG. 5;

fig. 9 is a further chart illustrating the flow of information corresponding to the fourth application of the digital map of fig. 5.

Detailed Description

Reference is first made to fig. 1 and 2. Fig. 1 shows an automated production process for bending glass sheets in automotive glazing, according to a schematic diagram. In the production process, flat, two-dimensional glass is processed, which has been cut and preprocessed beforehand. The resulting product is a so-called single-layer safety glass with a geometry that can be freely designed within the framework of certain boundary conditions. For this purpose, the plate is processed in two steps in the production system. First, the plate is bent by pressing in a form shaped under heat and then pre-tensioned by controlled cooling. Fig. 2 shows an exemplary production system for the automated production process of fig. 1 in a top view from above according to a schematic diagram. In the schematic diagram of fig. 1, the production process is carried out from left to right in time.

In this case, the plate 2 is heated first by the heating section, since in the cold state it is not possible to deform the glass. In the preheating zone 12 the plates 2 are heated by heating radiation 3, which is supplied above and below the roller bed 4 on which the plates 1 rest for transport. On the roller bed 4, the sheet 1 is fed to a bending zone 5. In the bending zone 5, hot air 6 is blown towards the panel 1 from below, which is received by a vertically movable mould 7. In order to generate a negative pressure at the surface of the mould, the mould 7 is provided with suction means for the panel 1. In order to achieve the desired geometry of the plate 2 to be produced, the surface of the mould 7 is specifically designed. Deformation of the plate 1 has been achieved by adapting the hot glass to the surface of the mould 7. The hot pressing ring 8, which can now be moved horizontally, travels as a counterpart of the die 7 below the die 7. In contrast to the die 7, the pressing ring 8 does not map the complete geometry of the plate 1, but merely provides a contact surface for the edge of the plate 1. The die 7 is then lowered and the plate 1 is pressed in a shaped manner between the die 7 and the pressing ring 8. After the pressing process, the plate 1 remains at the die 7 by means of the underpressure generated at the surface of the die 7 until the pressing ring 8 has returned and a horizontally movable cold preload ring 9 has been put in place, which is located beforehand in a pretensioning zone 10 beside the bending furnace 5. The underpressure is now eliminated and the plate 1 is lowered on the pretensioning ring 9. On the prestressing ring 9, the plate 1 is transported from the bending furnace 5 into the prestressing zone 10 and is prestressed and cooled by means of a cold air flow 11. The process is ended after the pretensioning and the plate 1 can be removed. The linear movement of the three central elements, the die 7, the extrusion ring 8 and the pretensioning ring 9, is schematically shown in fig. 2 according to the arrows.

In the production system 1, the boards 1 are automatically supplied, and the finished boards are automatically taken out and transferred to a downstream production step. The sequence of the production process within the production system 1 is carried out completely automatically, wherein the die 7, the pressing ring 8 and the pretensioning ring 9 can each be moved uniaxially by means of actuators (e.g. servomotors). The actuator-controlled movement of the die 7, the pressing ring 8 and the pre-tensioning ring 9 is decisive for the transport and the resulting geometry of the disk 1. In addition to the actuators for moving the central elements of the production system 1, further actuators are used in order to influence the process in a targeted manner. For example, the hot air supply and the cold air supply are controlled by flaps moved by actuators, and the separation of the different furnace zones is achieved by movable doors. However, the control of the axes of the die 7, the extrusion ring 8 and the pretensioning ring 9 of the production system 1 is process-determined, since their movements depend on one another and they run in the same working area (opereren). For example, the die 7 must be sunk into the pressing ring 8 in order to be able to perform the pressing step. Small deviations in position or in the temporal sequence of movements can therefore lead to undesired collisions, which can lead to costly stoppages of the production process, and in addition to this, can cause serious damage to the tool and to the production system 1 itself, due to the high speed and force of the servomotor. The control of the different axes is important for the successful production process, however, the control of the different axes is directed to the movement of the central element of the production system 1.

The automated production process for curved plates according to fig. 1 and 2 comprises a single die as well as a pressing ring and a pre-tensioning ring. This is to be understood only by way of example, wherein it is obvious that in principle a plurality of moulds can be used in order to produce very complex plate geometries. In addition, the hot pretensioning of the plates is also optional.

The process control is effected by a central SPS which is connected to all sensors of the production system 1 and on the basis of which the specified target values for the different axes to be controlled are determined. This is schematically illustrated in fig. 3. The SPS thus specifies a motion controller for the respective actuator based on the received sensor data. Depending on the setpoint value of the SPS, the lower motor regulator assumes the regulation of the actuator. Additionally, the SPS controls non-kinematic process effects such as furnace temperature and inflow pressure. The operator can access the SPS via the MMS and control the process flow, wherein specific parameters are entered in the MMS for this purpose.

Fig. 4 shows, according to a diagram, the different information flows in an automated production process for bending glass sheets, which is carried out, for example, in the production system 1 of fig. 2. The role of the human operator is to monitor and parameterize the production process. For this purpose, the operator can use MMS, by means of which the production process can be started or stopped and parameters for controlling the production process can be entered. An exemplary input screen window of an MMS is shown, in which a parameter value for the "pre-position B" (here, for example, 200) and a further parameter value for the "squeeze position 1" (here, for example, 250) can be manually entered. The parameters are transmitted to the SPS, by means of which the glass bending process is correspondingly controlled, wherein the SPS accesses sensor data for this purpose. The MMS makes it possible for the operator to be aware of the different process information provided by the SPS, which is not shown in detail here. The actual process flow as captured by the camera is shown on the monitor, which provides the operator with ancillary process information. However, the operator is not typically directly visually inspecting the production process because the axis movement occurs mostly within the enclosed bending zone. Furthermore, the view through the camera is limited because it is a high temperature environment, requiring the use of a particular camera with relatively poor resolution and viewing angle. Due to the system configuration, at least four viewing angles are typically required in order to fully reproduce the process flow. The operator monitors, in particular, system faults of the production, for example the loss of boards in the system, which can be caused by a faulty inflow of hot air or a negative pressure interruption.

Process parameterization is important for the production process to be carried out properly. Especially after retrofitting a new tool for a mold, it is necessary to adapt the parameters to the changed process and the new tool geometry. The programming of the SPS specifies the existing movement position of the axes and its basic flow structure. Today, the programming is only changed when a profound process change occurs, for example when a completely new motion step is introduced. The specific axis position values and the associated velocities and accelerations of the specific movement steps are objects parameterized by the operator. Although there are parameter specifications for each tool type, these need to be adapted manually to the properties of the plate or to the existing conditions, if necessary. The operator manually enters all parameter values into the MMS and only after actuating the start button the existing parameterization of the SPS is overwritten. The process is then performed with the new parameters.

According to the invention, an automated production system for curved sheets is provided with a digital image of the automated production process, which assists the operator. Utilizing existing IT infrastructure to seamlessly include the information flow of the digital image. Thus, control of the digital image is integrated into the MMS. As indicated in the opening paragraph, the digital image is a kinematically simulated glass bending process implemented in a procedural manner.

This is illustrated in a schematic diagram according to fig. 5, wherein the different information flows in the glass production process, including the digital image, are illustrated in a schematic diagram similar to fig. 4. In order to avoid unnecessary repetition, only the differences with respect to fig. 4 relating to the digital image are explained, otherwise reference is made to the above-described embodiment.

The digital image directly attached to the SPS includes multiple components. The central component is a 3D kinematic simulation of the glass production process, which is controlled here, for example, by a program-technical (simulated) SPS. The (simulated) sensor data can be sent to the simulated SPS. Attached to the 3D kinematic simulation is a combination of a communication server and a database, by which communication with the SPS is achieved for the real production process. The communication server is here constructed, for example, in the form of an OPC UA server. OCT UA is a bi-directional machine-to-machine communication protocol that was developed for process automation. The details are known to the person skilled in the art and are not important for understanding the invention, and therefore need not be discussed in more detail here. In particular, the use of OPC UA enables the transfer of current process data between SPS and 3D kinematic simulation of real production processes. The database stores the process data streams entering the OPC UA server. Therefore, 3D kinematic simulations can access current and earlier process data through OPC UA servers. The simulated SPS implements the original control program of the SPS for the real glass bending process. In addition to the camera picture, a visualization of the 3D kinematic simulation is shown to the operator on a monitor.

The 3D kinematic simulation comprises a geometry model of the production system in which the production process to be mapped is performed, and a kinematic simulation model. The 3D kinematics simulation maps the process flow of the production system influenced by the actuators, wherein the primary state variable is a position variable of the movable system component.

In the following, different preferred applications of the integrated digital image of the glass bending process of the production system 1 are explained.

The schematic diagram according to fig. 6 shows a first application case, in which the different information flows in the glass production process, including the digital image, are shown in a schematic diagram similar to fig. 5. This is essentially a simulation of the automated production process from the current sensor data, which is performed in parallel with the actual production process.

The flow of information from the glass bending process on the fly to the digital image is unilateral and automatic. The sensor data are transmitted to the 3D kinematics simulation by the SPS and OPC UA servers and are simultaneously archived in a database. Archiving in the database is only optional. On the basis of this sensor data stream, the simulation of the glass bending process is automatically carried out without the operator having to act, as long as the operator does not trigger further control commands. The mapping of the current process state continuously places the simulation model in the state of the real process, so that, in particular, the movements of the axes of the main components of the production system can be shown as 3D animations on the monitor. Therefore, it is possible to solve the problem of poor view of the process due to the high-temperature environment. Furthermore, the information that can already be displayed by MMS based on text is visualized vividly in a 3D animation if necessary. The temperature measurement can be shown as a text annotation in the correct region of the bending zone, the blowing with hot and cold air can be visualized by animation and provided with additional context (e.g. current pressure and temperature). The compression of information and visualization in 3D animation enables the operator to better and faster overview of the process.

This function can be further aided by methods that utilize process analysis. Instead of statically determining the choice of information in the visualization on a permanent basis, the most important information can be displayed dynamically in each case in a manner that is adapted to the current process state. For this purpose, the actual process data are assigned to the movement steps of the axes and are then prioritized according to the deviation from the setpoint value or mean value. Furthermore, throughput data from the process data can be calculated as new parameters. When the MMS displays a static cycle time based on the duration of the programmed motion sequence in the SPS, the average throughput, which is influenced by delays in upstream production steps, can be calculated in a 3D kinematic simulation environment.

Security checks can also be implemented using the current process data stream. Since the simulation model maps the geometry state of the system and, unlike SPS, has data on the dimensions of the currently loaded tool, the distance between the primary and secondary axes can be determined by digital mapping while the process is running. In 3D animation, distances that do not exceed a limit value can be highlighted to the operator. When the deviations are particularly severe, the simulation can also independently intervene in the process and send an instruction to stop the system to the SPS via the OPC UA server.

The same applies to the monitoring of the underpressure which holds the plate at the die after pressing. If the 3D kinematics simulation detects an interruption of the negative pressure from the data of the pressure sensor, the exact system state can be shown and frozen in a 3D animation in the event of a malfunction, so that the furnace operator can be provided with a better decision basis than a limited view by a camera for performing the necessary process intervention.

Fig. 7 shows a second application, in which the different information flows in the glass production process, including the digital image, are again shown in a schematic representation similar to fig. 5. In this case, this is essentially a failure analysis after disturbances in the true glass bending process.

In contrast to the application of fig. 6, the error analysis is triggered manually by the operator if necessary. After triggering the command by MMS, this command is forwarded to the 3D kinematic simulation. The simulation requests earlier sensor data in the OPC UA server. These sensor data are read from the database and used as a new data source for 3D kinematic simulations. The simulation model then goes through (durchlaufen) the past process state and is visualized similarly to using the current process data.

In a manufacturing enterprise, two exemplary scenarios are particularly important for this application. First, system faults, such as unplanned outages, glass loss in the furnace, or collisions, can be checked. From the time stamp of the fault, the cycle of the fault can be identified and visualized for the operator. Comparing the process data of a faulty production cycle with the process data of an earlier non-faulty cycle in the database with the same parameterization and tooling, can highlight anomalous or off-nominal values. Thus, the digital map facilitates failure cause analysis by identifying and visualizing potential failure sources. The responsible person can perform the first assessment of the degree of failure and possible need for maintenance directly at the system without additional auxiliary devices. A second use case of the failure analysis relates to a failed glass panel. Each manufactured board has a unique identification code that is stored in the database along with the earlier process data. Thus, each board can be assigned a data map of its individual production cycle. If the measuring station downstream of the glass bending process increasingly determines deviations from the nominal geometry, the operator can visualize the production of this sheet again by numerical mapping on the basis of the sheet number. Similar to the checking of system failures, the 3D animation of the production cycle of a failed board contains additional information from the comparison with the previous cycle having the same configuration. This assists the operator in determining: whether and how parameter adjustments need to be made, or whether faulty system behavior is the cause of the geometry deviation.

A third application is shown in accordance with fig. 8, wherein, likewise, the different information flows in the glass production process, including the digital image, are shown in a schematic diagram similar to fig. 5. In this case, this is essentially a review of the new parameters, in particular to avoid system component collisions and to automatically optimize the new parameters on this basis.

Testing of new parameters for the operation of the production process is a very important auxiliary function of the digital map for the operator. Due to the frequency of the parameter changes and the fact that even just one parameter is mistaken, serious consequences result, a simple and reliable method for risk-free pre-review of the changes is obtained. In order to use this method, instead of directly parameterizing the SPS of the real production process with the new values, the operator preferably enters the new parameter values into the normal input screen window of the MMS and manipulates, for example, the newly added switch surface in order to trigger the simulation. The parameters are transmitted by the SPS and OPC UA servers to the 3D kinematic simulation, which parameterizes the simulated SPS again. The 3D kinematic simulation stops, for example, the ongoing processing of the current process data and is therefore independent of the ongoing production process. The simulated SPS implements a control program, and the actuators of the simulation model are controlled by the read sensor values of the control program. Thus, the simulation environment simulates the process flow with the original control program under the operator's new parameterized recommendations and visualizes the process flow on the monitor. At the same time, the simulation calculates the resulting cycle time of the new parameter configuration and whether a collision occurred. Thus, 3D animation enables the operator to verify visually and qualitatively the new process flow, including collisions that may occur. The simulation results regarding the cycle time and the system components that are possibly involved in the collision are also transmitted to the MMS, for example as text, and displayed. At the end of the review cycle, the operator finally makes a decision on applying the new parameterization, the operator being able to confirm or reject this new parameterization by pressing a key.

The optimization of the parameters, which is preferably implemented in a complementary manner, is carried out largely analogously to the new parameterized test. For this purpose, the operator enters the parameter sets into the MMS as a basis for an optimization procedure, which is processed by the digital image. Instead of performing one simulation experience (simullationsdurchlauf), multiple experiences (Durchl ä ufe) are performed, which preferably omit 3D animation to save time. Between the experiences, the parameters are adjusted stepwise according to, for example, an optimization algorithm for cycle time minimization. The parameter configuration with the smallest cycle time, which is nevertheless always normal and collision-free, is visualized and the associated parameters are shown in the input screen window of the MMS. The operator needs to finally confirm the parameterization recommendation before applying it to the real process.

In fig. 9, a fourth application case is illustrated according to the schematic diagram. Which is essentially an actuator in the glass bending process that avoids collisions of system components and automatically prevents control signals from being transmitted to the glass bending process.

The operator preferably enters the new parameter values into the normal entry screen window of the MMS and actuates the switch surface in order to trigger the actual production process. However, the SPS passes the parameter values to the OPC UA server and 3D kinematic simulation before forwarding the corresponding control signals to the actuators. The simulated SPS implements a control program, and the actuators of the simulation model are controlled by the read sensor values of the control program. The simulation environment therefore simulates the process flow with the original control program under the new parameterization recommendation of the operator, wherein possible collisions of the process flow are checked. If a collision is detected, the transmission of the control signal to the actuator is prevented, for example by the SPS itself, wherein this can also be achieved by a separate control device subordinate to the actuator. In fig. 9, this is symbolized by a traffic light with a bar. If no collision is identified, a control signal is transmitted to the actuator and the process flow is initiated. If a collision is detected or if no collision is detected, it is also advantageous to display the simulated movement sequence of the system components as a 3D animation on a monitor. This facilitates the operator to select new parameter values. It is also advantageous to display further information of the process flow.

From the above, it can be seen that the present invention provides a novel automated production process for glass bending and a production system with digital images of the automated production process, in which collisions of system components can be reliably and safely avoided. There is no undesirable downtime and increased production costs in the event of a collision due to replacement of damaged parts.

List of reference numerals

1 production system

2 board

3 heating radiation

4-roller bed

5 bending zone

6 Hot air

7 mould

8 extrusion ring

9 Pre-tightening ring

10 Preload zone

11 stream of cold air

12 preheating zone

Claims (11)

1. Automated production process for curved plates, in which a plate can be processed by means of a movable system component, wherein the movable system component can be controlled by a programmable logic control device on the basis of manually input parameter values, wherein the programmable logic control device can output control signals to actuators of the movable system component and can receive sensor signals of sensors for detecting the actual state of the actuators,

-manually entered parameter values for controlling the movable system components are transferred to a digital image of the automated production process,

checking for collisions of the system components due to a movement of at least one movable system component,

-wherein in case of a collision a control signal based on the parameter value is prevented from being forwarded by the programmable logic control device to the actuator,

or

-outputting a control signal based on the parameter value from the programmable logic control device to the actuator in case no collision occurs.

2. An automated production process for curved sheets according to claim 1, in which, in the event of a collision, corresponding information is output on at least one monitor.

3. Automated production process for curved panels according to claim 2, in which colliding system components are shown on the at least one monitor in a contrasting manner in terms of color to non-colliding system components.

4. An automated production process for curved sheets according to any one of claims 2 to 3, in which a simulated motion flow of the movable system component is shown on the at least one monitor in an enlarged schematic view and/or in a different perspective.

5. An automated production process for curved sheets according to any one of claims 2 to 4, in which a simulated flow of motion of the movable system component is shown in an externally inaccessible perspective on the at least one monitor.

6. An automated production process for curved sheets according to any one of claims 2 to 5, in which a simulated motion flow of the movable system component is shown on the at least one monitor after a time delay.

7. An automated production process for curved sheets according to any one of claims 2 to 6, in which at least one information relating to the process flow, in addition to a visualization of the motion flow of the movable system component, is shown on the at least one monitor.

8. An automated production process for curved sheets according to claim 7, in which at least one displacement time chart of movable system components is shown on the at least one monitor.

9. An automated production process for curved plates according to any one of claims 1 to 8, in which process, in the programmable logic control device, the forwarding of control signals based on the parameter values to the actuators is prevented.

10. An automated production process for curved sheets according to any one of claims 1 to 8, in which process, in an actuator control device controlled by the programmable logic control device, forwarding of a control signal based on the parameter value to the actuator is prevented.

11. Automated production system for curved plates for carrying out the method according to one of claims 1 to 10, having a movable system component for processing a plate, wherein the movable system component can be controlled by a programmable logic control device on the basis of manually input parameter values, wherein the programmable logic control device can output control signals to actuators of the movable system component and can receive sensor signals of sensors for detecting the actual state of the actuators, having a digital image of the automated production process, and being programmed such that the manually input parameter values for controlling the movement of the movable system component are transmitted to the digital image, a collision of the system components due to the movement of at least one movable system component is checked, wherein in the event of a collision a control signal based on the parameter value is prevented from being forwarded by the programmable logic control device to the actuator, or in the event of no collision a control signal based on the parameter value is output by the programmable logic control device to the actuator.

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