EP2153909A2 - Processing concept - Google Patents

Abstract

The method involves processing work pieces (1, 2) e.g. bumper, in two processing steps in spatially distant processing regions (52, 54, 56) i.e. painting booth. The work pieces are transported between the processing regions by a common conveyor system. The work pieces are fed and conveyed on the conveyor paths (58, 60, 62) in the processing regions for each processing step, where the paths are associated with the conveyor system. The work pieces are fed and/or conveyed into the common processing region (54) by opposite sides of one of the paths (60) that runs transverse to the common region. An independent claim is also included for a processing region for processing work pieces.

Description

The invention relates to a method for processing a plurality of first and second workpieces.

It is well known that industrial products such as automobile bodies are assembled from a plurality of individual workpieces. Due to the ever-increasing demands of customers for customization, the variety of shapes of the workpieces to be produced is increasing. But the variety of colors, such as the car bodies and the associated attachments such as bumpers or mirror housing, is steadily increasing.

As a result, in particular when varnishing such workpieces between different customer-specific variants of one and the same workpiece type, such as a bumper, sometimes considerable differences in the required effort of the respective processing or painting process result.

For example, a bumper with settings for fog lights requires a higher painting effort than the same bumper without sacrifices. Also, the painting of a workpiece in a difficult-to-paint color, such as yellow, which is characterized by a low opacity, requires an increased Lackieraufwand or even an additional Lackierschritt compared to the painting of the same workpiece, for example in the color black, which has a high opacity. That is, a workpiece is required, repeatedly painted, preferably a flash-off time between the painting steps is provided.

In particular, in automotive attachments to paint in a industrial painting a variety of differently shaped workpieces in a variety of different colors, resulting in a different time in each case in the processing. The workpieces, for example, also undergo a different number of process steps, depending on their material to be varnished, some are repeated (2 layers application), some are omitted (for example, blowing).

Corresponding industrial painting plants are usually designed for a plurality of different workpieces to be painted. The workpieces are transported by means of a conveyor system from one processing area of the paint shop to the next respectively. Often, such conveyor systems have the structure of a closed ring, the unpainted workpieces are usually mounted in a task area of the paint shop on a transported from the conveyor system workpiece carrier. Together with the workpiece carrier, the workpieces pass through the respective processing areas of the painting installation as on a string of beads and are removed from the workpiece carrier as finished workpieces in a removal area of the painting installation. The now empty workpiece carrier is then conveyed back to the receiving area.

In the WO 2005/120733 For example, the structure of such a conveyor system is shown with different processing areas. There is also the possibility of ejecting workpiece carriers at a branch of the conveying path from the circular structure to a further processing region or a bypass and subsequently feeding them back into the circular structure in the conveying direction.

A disadvantage of this approach is in particular that at a different required processing costs for first, second and other workpieces, which are at least partially processed in common processing areas, each of the highest processing costs is decisive for the required processing capacity the respective processing areas. Depending on the workpieces and processing steps to be performed, there are times in which the processing capacities in the processing areas are not used.

Based on this prior art, it is an object of the invention to provide a method which allows a better utilization of processing capacities. The object of the invention is also to specify a corresponding processing area for this purpose.

This object is achieved by a method for processing a plurality of first and second workpieces having the features specified in claim 1.

Accordingly, the method is characterized in that the workpieces are sequentially fed to an at least partially common machining process, wherein workpieces are processed in at least two processing steps in at least two spatially remote processing areas and a transport of the workpieces between the respective processing areas by a common conveyor system, wherein the Workpieces for a respective processing step on a conveyor system associated conveyor line in the respective processing area and be conveyed and wherein according to the method first and second workpieces in each case at least one common processing area of opposite sides of the transversely extending through the processing area arranged conveying path one and / or discharged become.

The structure of the conveyor system is necessarily not exclusively as annular, but rather to be regarded as at least partially mesh-shaped. The mesh-shaped structure allows the selection of an individual conveying path for a workpiece or for a group of workpieces through the respective processing areas. The conveying path is preferably to be determined so that the existing processing capacities of the processing areas are used as completely as possible.

Depending on the amount of workpieces to be machined, a common conveying path is conceivable for a larger number of first workpieces to be machined one after the other, which is then changed for a subsequent larger number of second workpieces to be machined successively, for example the shape of the first and second workpieces is identical, but other processing steps are required.

A feature of the method essential to the invention is that the conveying path is operated bidirectionally by at least one processing area as required, whereas according to the prior art, the conveying paths are operated by processing areas only in one direction. This allows a shortened conveying path of a workpiece between different mesh-like associated with a conveyor system processing areas, because now not only can be promoted from a given page in a processing area, but a transfer from both sides is possible. Transports of the workpiece outside of the working area from its second end to its first end to pass thereafter for processing from the first end to the second end, thus eliminating advantageously. The meshed conveyor system is thus easier and the transport times are reduced.

Further variants of the method according to the invention are characterized in that a coating process takes place in at least one processing step and that the coating process takes place in a painting booth by means of at least one painting robot.

Especially coating or painting operations are characterized by a high variety of variants of the workpieces to be painted, which is why the advantages of the method according to the invention are particularly significant here.

The use of a painting robot for the coating of workpieces advantageously allows a reproducible coating quality with a previously known processing time for a respective processing step. The possibilities of an improved utilization of the existing processing capacities of the processing areas, For example, by means of a higher-level control system, this can be increased.

A further embodiment of the method according to the invention is characterized in that in at least one processing step, a drying process of the workpiece takes place, for example after a painting or a cleaning process. The corresponding processing area in this case has, for example, an oven or radiation dryer. But even a cleaning of a workpiece in a designated processing area is to be regarded as a possible processing step.

In a variant of the method according to the invention, at least first workpieces are conveyed in and out of the same side of the conveying path in the at least one common processing region. The delivery times of the workpieces between the processing areas are thereby further reducible depending on given boundary conditions.

It also proves to be advantageous with regard to a reduced conveying time that a workpiece is processed at least partially simultaneously during conveying through a machining area therein.

In a preferred embodiment, a plurality of processing steps are performed on a conveyed workpiece in a designated processing area. The funding period can be further reduced.

In a further embodiment of the method according to the invention, at least one processing step for first and second workpieces takes place differently in the at least one common processing region. Thus, for example, first workpieces are painted with a basecoat, while second workpieces are painted with a primer coat, which usually takes place in different processing areas. The possibilities of improved utilization of the processing capacities are thus further increased.

In a further embodiment of the subject invention, workpieces are arranged on a workpiece carrier before processing and then fed to the processing. As a result, the conveying of the workpieces is simplified with reduced assembly tolerances. The conveying takes place preferably with a floor conveyor or with an overhead conveyor.

A further embodiment of the method is characterized in that the conveyor system and / or the associated conveyor lines are operated at least in sections with a respectively adapted conveyor speed. As a result, the conveying flow of the workpieces between the different processing areas can be made even more variable and the utilization of the existing processing capacities can be further increased. Similar advantages result from the at least section-wise operation of the conveyor system and / or the associated conveyor sections in a respectively adapted conveying direction.

In a further variant of the method, an at least partially different conveying path for first and second workpieces is predetermined by means of at least one switchable branch in the conveying system. This is for example a switch or a turntable, which is connected on at least three sides with the further conveyor system. The conveying flow of the workpieces between the different processing areas is therefore particularly easy to influence.

In a preferred variant of the method, workpieces are temporarily stored between two processing steps in a buffer area of the conveyor system. This allows a temporal equalization of possibly resulting peaks of required processing capacity and provides a further control option for improved utilization of the processing capabilities.

In a particularly preferred variant of the method according to the invention, after a transfer-related transition of a workpiece carrier and / or a workpiece to a conveyor line which leads into a common processing area, before being conveyed into the processing area, a data carrier connected to the workpiece carrier and / or the workpiece is automatically read a reading device.

Such data carriers contain information about the relevant workpiece and the processing steps to be performed. This information is supplied, for example, to a higher-level control system, which, moreover, receives data from further processing areas.

Based on these data and other production data, the control system determines, for example, automatically the respective conveying paths of the workpieces and / or goods carriers and controls the conveying flow of the workpieces by switching the corresponding branches in the conveyor system.

By reading the data carriers at the reading points of the common processing area with bidirectional conveying system, information is made available to the control system which simplifies the reliable control of the conveying flow and the processing steps of the workpieces.

The object according to the invention is also achieved by a machining area for machining workpieces corresponding to the method according to one of claims 1 to 15, with a conveying system associated with a conveyor system for feeding in and out of workpiece carriers and / or workpieces arranged thereon.

The processing area is characterized in that the conveyor line can be operated bidirectionally and that at least one reading device for reading one connected to a workpiece and / or workpiece carrier is connected between the two connection points of the conveyor line to the further conveyor system on the one hand and the entry or exit point of the conveyor line in the processing area Data carrier is provided.

Such data carriers contain information about the relevant workpiece and the processing steps to be performed. In the case of an annular conveyor system, a single reading operation is usually sufficient before the workpiece is conveyed into the machining area in which the first machining step is carried out. The read data are then for example via a higher-level control system forwarded to the respective subsequent processing area. When conveying the workpiece in the subsequent processing area, only the information is detected that a workpiece has been conveyed into this, the detailed information is taken from the previous processing area. Along a conveying path without branches, this is sufficient because the sequence of the workpieces along the conveying path is not changeable.

A bidirectional conveying path through a processing area is inevitably provided with branching possibilities at its two ends if it is integrated in a meshed conveyor system. The order of the workpieces is therefore changeable. Several along a common conveyor line arranged processing areas are to be regarded in this context as a single processing area, which is provided at its two ends, each with a reading location.

A control of the processing steps in a processing area with bidirectional conveyor system is greatly simplified by a double-sided reading device.

Further advantageous embodiment possibilities can be found in the further dependent claims.

Reference to the embodiments illustrated in the drawings, the invention, further embodiments and other advantages will be described in detail.

Fig. 1 a

ein erstes Bearbeitungssystem in einem ersten Verfahrenszustand,

Fig. 1 b

das erste Bearbeitungssystem in einem zweiten Verfahrenszustand,

Fig. 1c

das erste Bearbeitungssystem in einem dritten Verfahrenszustand,

Fig. 2a

ein zweites Bearbeitungssystem in einem ersten Verfahrenszustand,

Fig. 2b

das zweite Bearbeitungssystem in einem zweiten Verfahrenszustand und

Fig. 3

ein Beispiel für einen Werkstückträger mit Werkstücken

Show it:

Fig. 1 a

a first processing system in a first method state,

Fig. 1 b

the first processing system in a second process state,

Fig. 1c

the first processing system in a third process state,

Fig. 2a

a second processing system in a first process state,

Fig. 2b

the second processing system in a second process state and

Fig. 3

an example of a workpiece carrier with workpieces

Fig. 1 a shows a first processing system 30 in a first process state 10a. The processing system 30 has a first 12, a second 14 and a third 16 processing area for processing workpieces. Each processing area is to be regarded in this example as delimited paint booth, through which a respective conveyor line 18, 20, 22 is arranged.

By means of the conveyor lines 18, 20, 22 are workpieces 1, 2, which are arranged for example on a workpiece carrier, in the paint booths 12, 14, 16 on and also ausförderbar. Each paint booth 12, 14, 16 is equipped with two paint robots 36, with which a variety of different paints can be applied. However, the number of painting robots can also be only one or even more, for example eight, or else a purely manual machining area is also conceivable. Preferably, a painting robot 36 is provided with 6 degrees of freedom of movement, because this allows reaching each space point in the respective working area of the robot 36 with each orientation, but also an arrangement of such a robot 36 on a so-called seventh axis or a support column is of course within the spirit of the invention , The robots 36 may differ from each other, for example in their execution and in the type or number of applicable lacquers. A painting of a workpiece during conveyance through the paint booth is provided in both conveying directions.

The paint booths 12, 14, 16 are an exemplary example of a processing area, a real industrial Lackieranlage has in addition to the paint booths for the various paints, for example, cleaning, drying, rework and / or buffer areas, which of course also the possibility of conveyor technology Bypass is given.

The conveyor system has the three conveying lines 18, 20, 22 crossing the paint booths, which are conveyed to two meshes at a first 32 and a second switchable diversion 34, wherein a further conveyor line is connected to each switchable branch, via which the Workpieces 1, 2 can be conveyed into the processing system 30 or out of this addition. Usually these two conveyor lines are outside of the processing system connected to each other, so that workpiece carrier after removal of the finished painted workpieces can be re-populated with unpainted workpieces and the processing system to be re-supplied.

In the first method state 10a shown, only a plurality of first workpieces 1 are to be painted, which are indicated as a triangle, but in reality can be, for example, bumpers for automobile bodies or automobile bodies themselves. The term first workpieces does not necessarily mean that first workpieces must resemble each other in shape and / or the steps to be performed, but rather comprises a group of workpieces to be painted, possibly even selected at random. Of course, the invention concept also any number of other groups of workpieces, ie third, fourth, ..., detected.

In the illustrated example 10a, the first workpieces 1 are to be regarded as equally shaped workpieces, on which only one coat of varnish in possibly different colors has to be made. The first workpieces 1 conveyed into the processing area 30 are distributed at the first switchable branch 32 to the three processing areas 12, 14, 16, in which they are then painted during the throughfeed. Thereafter, they are reunited at the second switchable branch 34 on a common conveyor line and discharged. Depending on the colors to be applied, an assignment of different colors to the processing areas makes sense to reduce the number of color changes and the associated color change losses.

The Fig. 1b shows the same processing system 30 now in a second process state 10b. There are only second workpieces 2 to paint, which are on the one hand larger than the first workpieces 1 and also require three different paint jobs. The first 12 and second 14 processing area are only intended to carry out the first and second coating application - for example, the application of a base coat - the third processing area is intended to perform in addition to the first and second coating order and the third coating application - for example, the application of a clearcoat ,

In the process state 10b all 3 paint booths are now conveyor technology in series and no longer connected in parallel and are sequentially passed through by the second workpieces 2. By means of this series connection, precisely one processing step is carried out in each processing region, which advantageously reduces, for example, the number of necessary color changes.

The Fig. 1c shows the same processing system 30 now in a third process state 10c. First 1 and second 2 workpieces are processed together sequentially in the processing area 30. There are first 1 and second 2 workpieces, each with a layer of base coat to paint, with both types of workpieces for selected paints, such as the color yellow, a second paint layer of the color yellow is applied.

Only second workpieces 2 are conveyed and processed by the second processing region 14, while only the first workpieces 1 are conveyed and processed by the third processing region 16. In the first processing area 12, if necessary, from the left first yellow in the color to be painted workpieces and discharged, while from the right, if necessary, second in the color yellow to be painted workpieces and be discharged, wherein in the first processing area 12 each one of the two in the Color yellow necessary paint jobs done.

Fig. 2a shows a similar second processing system 70 with 3 processing areas 52, 54, 56, which are each equipped with painting robots 76. The three conveyor sections 58, 60, 62 crossing the processing areas are connected to each other at a total of six switchable branches, four of which are designated by the reference numbers 72, 74, 78, 80 in FIG. Also included is a buffer area 90 of the conveyor system, in which workpieces can be temporarily stored. Shown in this example are also a first 82 and a second reading device 84 at the beginning of the unidirectionally operated conveyor lines 58, 62 of the fourth 52 and sixth 56 processing area and a third 86 and fourth 88 reading device on both sides of the bidirectionally operable conveying path 60 of the fifth processing area 54.

Due to the meshing of the conveyor lines of the conveyor system, it is advantageous to provide such reading devices, so as to ensure a clear identification of transferred to a conveyor line workpieces, the workpieces or the workpiece carriers are provided with a corresponding data carrier containing the identification data. The information read by the reading device is then preferably transmitted to a higher-level control system, not shown, for example a data processing device. On the basis of these data and other production data, corresponding conveying paths are determined for the respective workpieces, taking into account the respective boundary conditions. The results are transmitted from the control system back to the processing system and implemented there.

The Fig. 2a shows the second processing system 70 in a first process state 50a. There are first and second workpieces, each with two paint layers to apply, the painting time for the first 1 workpieces is significantly smaller than for the second 2 workpieces and wherein between both paint jobs a Abdunstzeit in the buffer area 90 is required. A plurality of successive second workpieces 2 has already been provided with the first lacquer layer. A part of the second workpieces is still in the buffer area 90, another has already left the buffer area for painting the second paint layer. In order to allow for a correspondingly high processing throughput despite the increased painting time for second workpieces 2, the painting takes place in parallel in the fifth 54 and sixth 56 processing areas, so that the buffer area 90 is accelerated empty.

Prompted into the processing system 70 and painted in the fourth processing area 52 is a plurality of successive first workpieces 1. Due to the lower Lackieraufwandes corresponds to the time throughput of the fourth processing area 52 on first workpieces 1 in about the time throughput of the parallel fifth 54 and sixth 56 processing areas on second workpieces 2.

The Fig. 2b shows the second processing system 70 in a second process state 50b. From the buffer area 90 now all second workpieces 2 are discharged. In the fifth processing region 54, the first coating application for first workpieces 1 takes place parallel to the fourth processing region 52 in the reverse direction of conveyance. The resulting increased throughput of machined workpieces is thereby absorbed by the intermediate buffer 90.

In a further, not shown process state with only similar workpieces with comparable processing time, for example, the fifth processing area 54 would be operated alternately for a certain number of successive workpieces parallel to the fourth 52 or sixth 56 processing area, wherein the buffer area 90, the resulting fluctuations in the throughput of Balances workpieces. In this case, first and second workpieces would be considered each to be a number of successive like workpieces, which even require the same processing steps.

Fig. 3 shows an example of a workpiece carrier 104 with workpieces 106, 108, which are indicated as bumpers for automobile bodies. The workpiece carrier 104 is located on a conveyor line 102, a bottom conveyor with rollers 112. Connected to the workpiece carrier 104 is a data carrier 110 which contains data about the workpieces 106, 108 to be processed and which can be read by a reading device. However, the data carrier can also contain only one serial number, wherein an assignment of the serial number to the workpieces to be processed 106, 108 takes place in a separate allocation table, which is also included for example in the higher-level control system.

Bezugiszeichenliste

1

first workpiece

2

second workpiece

10a

first processing system in a first process state

10b

first processing system in a second process state

10c

first processing system in a third process state

12

first processing area

14

second processing area

16

third processing area

18

Conveyor line of the first processing area

20

Conveyor of the second processing area

22

Conveyor line of the third processing area

30

first processing system

32

first switchable branch

34

second switchable branch

36

first processing device

50a

second processing system in a first process state

50b

second processing system in a second process state

52

fourth processing area

54

fifth processing area

56

sixth processing area

58

Conveyor of the fourth processing area

60

Conveyor of the fifth processing area

62

Conveyor of the sixth processing area

70

second processing system with buffer of the conveyor system

72

third switchable branch

74

fourth switchable branch

76

second processing device

78

fifth switchable branch

80

sixth switchable branch

82

first reading device

84

second reading device

86

third reading device

88

fourth reading device

90

Buffer area of the conveyor system

100

Example of a workpiece carrier with workpieces

102

Part of a conveyor line

104

Workpiece carrier

106

first attachment

108

second attachment

110

disk

112

role

Claims (18)

Method for processing a multiplicity of first (1) and second (2) workpieces which are fed sequentially to an at least partially common machining process, wherein workpieces (1, 2, 106, 108) are processed in at least two processing steps in at least two spatially remote machining areas (12 , 14, 16, 52, 54, 56) and a transport of the workpieces (1, 2, 106, 108) between the respective processing areas (12, 14, 16, 52, 54, 56) takes place through a common conveyor system, wherein the workpieces (1, 2, 106, 108) for a respective processing step on a conveying path (18, 20, 22, 58, 60, 62, 102) belonging to the conveyor system are fed into the respective processing region (12, 14, 16, 52, 54, 56) are fed in and out and according to the method first (1) and second (2) workpieces in at least one common processing area (12, 14, 54) from opposite sides of the transverse through the processing area (12, 14, 54) ver continuously arranged conveyor line (18, 20, 60) each one and / or discharged. A method according to claim 1, characterized in that in at least one processing step, a coating process takes place. A method according to claim 2, characterized in that the coating process takes place in a painting booth by means of at least one painting robot. Method according to one of claims 1 to 3, characterized in that in at least one processing step , a drying process takes place. Method according to one of the preceding claims, characterized in that at least first workpieces (1) in the at least one common processing area (12) from the same side of the conveying path (18) and are conveyed out. Method according to one of the preceding claims, characterized in that a workpiece (1, 2, 106, 108) during the conveying through a processing area (12, 14, 16, 52, 54, 56) at the same time at least partially processed therein. Method according to one of the preceding claims, characterized in that in a processing area (12, 14, 16, 52, 54, 56) on a conveyed workpiece (1, 2, 106, 108) a plurality of processing steps are performed. Method according to one of the preceding claims, characterized in that in the at least one common processing area (12, 14, 54) at least one processing step for first (1) and second (2) workpieces takes place differently. Method according to one of the preceding claims, characterized in that workpieces (1, 2, 106, 108) are arranged before processing on a workpiece carrier (104) and then fed to the processing. Method according to one of the preceding claims, characterized in that workpieces (1, 2, 106, 108) are conveyed with a floor or overhead conveyor. Method according to one of the preceding claims, characterized in that the conveyor system and / or the associated conveyor lines (18, 20, 22, 58, 60, 62, 102) are operated at least in sections with a respectively adapted conveying speed. Method according to one of the preceding claims, characterized in that the conveyor system and / or the associated conveyor lines (18, 20, 22, 58, 60, 62, 102) are operated at least in sections in a respective adapted conveying direction. Method according to one of the preceding claims, characterized in that an at least partially different conveying path for first and second workpieces by means of at least one switchable branch (32, 34, 72, 74, 78, 80) is predetermined in the conveyor system. Method according to one of the preceding claims, characterized in that workpieces (1, 2, 106, 108) between two processing steps in a buffer area (90) of the conveyor system are temporarily stored. Method according to one of claims 9 to 14, characterized in that after a conveying technology-related transition of a workpiece carrier (104) and / or a workpiece (1, 2, 106, 108) on a conveying path (18, 20, 60) in a common processing area (12, 14, 54), before being conveyed into the processing area, a data carrier (110) connected to the workpiece carrier (104) and / or the workpiece is automatically read by means of a reading device (82, 84, 86, 88). Machining area (12, 14, 16, 52, 54, 56) for machining workpieces (1, 2, 106, 108) according to the method according to one of claims 1 to 15, with a conveyor line (18, 20, 22, 58, 60, 62, 102) for feeding in and out of workpiece carriers (104) and / or workpieces (1, 2, 106, 108) arranged thereon, characterized in that the conveying path (18, 20, 22, 58, 60, 62) is bidirectionally operable and that between the two connection points (32, 34, 72, 74, 78, 80) of the conveyor line (18, 20, 22, 58, 60, 62) to the further conveyor system on the one hand and the A - Or exit point of the conveyor line (18, 20, 22, 58, 60, 62) in the processing area (12, 14, 16, 52, 54, 56) on the other hand in each case at least one reading device (82, 84, 86, 88) for reading a data carrier (110) connected to a workpiece (1, 2, 106, 108) and / or workpiece carrier (104) is provided. Machining area according to claim 16, characterized in that this is a painting booth. Machining area according to claim 17, characterized in that painting robots are provided for the machining of the workpieces (1, 2, 106, 108).

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