JP2011221898A - Die wear predictor and production management system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a die wear predictor allowing accurate prediction of die wear conditions, and a production management system.SOLUTION: An wear amount of a die is predicted based on die use conditions, and the predicted wear amount of the die is used to predict a shape of a worn die. Based on the shape of the worn die, the workpiece quality of workpieces manufactured with the die is predicted. Based on the predicted workpiece quality, replacement timing of the die is predicted. Thus the die wear predictor enables the prediction of transition of the worn die shape and the workpiece quality, therefore allowing determination of the replacement timing of the die which is a cause of impairing the workpiece quality.

Description

  The present invention relates to a mold wear prediction apparatus and a production management system.

  Patent Document 1 discloses a technique for predicting the wear amount of a mold and predicting the life of the mold from the predicted wear amount.

JP 2002-321032 A

  However, the shape of the mold changes with the wear of the mold, and the volume of the cavity increases, so in reality, when the workpiece is manufactured, a thin portion where the material cannot reach is generated in the workpiece. Depending on the part, the quality was judged to be out of specification, and the mold was exchanged.

  That is, the wear of the mold affects the dimensions and shape of the workpiece, and even before the life predicted from the wear amount is reached, the quality of the workpiece may be judged to be out of specification. The mold life and the timing for actually exchanging the mold did not always coincide.

  In the past, production plans were issued, but they could not be used for the calculation of mold inventory and the relationship with quality trends. Based on the mold change was carried out.

  As described above, the production management system based on the experience that has not been quantitatively predicted in advance has a large amount of mold stock and work stock, which deteriorates management cash flow. For example, excessive mold stock is performed in order to cope with sudden mold change, and excessive stock of workpieces to prevent delay in supply of the post-process due to poor quality due to mold wear has been a problem.

  The present invention has been made in view of the above points, and an object thereof is to obtain a mold wear prediction apparatus and a production management system capable of accurately predicting a wear state of a mold.

  The mold wear prediction apparatus of the present invention that solves the above problems is a mold wear prediction apparatus that predicts the wear state of a mold, and is a mold wear amount prediction means that predicts a mold wear amount based on the use conditions of the mold. And shape predicting means for predicting the shape after mold wear using the mold wear amount predicted by the mold wear amount predicting means.

  According to the mold wear prediction apparatus of the present invention, since the shape after mold wear is predicted based on the amount of mold wear, the work quality can be predicted based on the shape after mold wear, and the mold is based on the work quality. The exchange time can be predicted. Therefore, for example, transition of the mold wear shape and work quality for each lot can be predicted, and the replacement time of the mold that causes the work quality to be inhibited can be determined.

  The shape prediction means sets a plurality of nodes on and inside the mold, and calculates a normal passing through the surface nodes set on the surface of the mold among the set nodes. The position of the surface node is moved in the wear direction by the amount of die wear at the surface node along the normal, and the post-wear shape is predicted based on the position of the surface contact after the movement. Is preferable, and thus the shape after mold wear can be accurately predicted.

  Preferably, the shape predicting means is configured to reset all nodes when at least a part of all the nodes is overlapped after moving the surface nodes. When the overlapping portion between the nodes occurs, it is impossible to continue the calculation for moving the surface nodes. Since it is rearranged, the calculation for moving the surface node can be continued. Therefore, the shape after mold wear can be accurately predicted based on the amount of mold wear.

  It is preferable that the die wear amount predicting means predicts the die wear amount for each lot set in advance, and the shape predicting means predicts the shape after die wear of each lot based on the die wear amount. Therefore, transition of the mold wear shape and work quality for each lot can be predicted, and the replacement time of the mold that causes the work quality to be inhibited can be determined.

  Moreover, it is preferable that the mold wear prediction apparatus of the present invention includes a work quality prediction unit that predicts the work quality of a work manufactured by the forming die based on the post-mold wear shape predicted by the shape prediction unit. . And it is preferable to have a replacement time prediction means for predicting the replacement time of the mold based on the work quality predicted by the work quality prediction means. Moreover, it is preferable to have a schedule plan creating means for creating a schedule for replacing the mold based on the mold replacement time predicted by the replacement time predicting means. And it is preferable to have the schedule plan information transmission means which transmits the information of the schedule plan created by the schedule plan creation means to the terminal for mold makers.

  The production management system of the present invention is a production management system for managing the replacement time of a mold, and a mold wear amount predicting means for predicting a mold wear amount based on a use condition of the mold, and the mold wear amount prediction Shape prediction means for predicting the shape after mold wear using the die wear amount predicted by the means, and predicting the work quality of the workpiece manufactured by the mold based on the shape after mold wear predicted by the shape prediction means Workpiece quality prediction means, replacement time prediction means for predicting the replacement time of the mold based on the work quality predicted by the work quality prediction means, and based on the replacement time of the mold predicted by the replacement time prediction means A schedule plan creating means for creating a schedule for exchanging the mold, and a schedule meter for transmitting the schedule information created by the schedule plan creating means to the mold maker terminal. It is characterized by having information transmission means.

  According to the production management system of the present invention, the schedule for exchanging the mold is created based on the production plan, and information on the schedule is transmitted to the terminal for the mold producer. Based on this information, the corresponding mold can be created and delivered in accordance with the due date. Therefore, the user of the mold can receive delivery of the mold at an appropriate timing from the mold maker, and can reduce the excessive inventory of the mold.

  According to the mold wear prediction apparatus of the present invention, since the shape after mold wear is predicted based on the amount of mold wear, the work quality can be predicted based on the shape after mold wear, and the mold is based on the work quality. The exchange time can be predicted. Therefore, for example, transition of the mold wear shape and work quality for each lot can be predicted, and the replacement time of the mold that causes the work quality to be inhibited can be determined.

  Then, according to the production management system of the present invention, a schedule for exchanging the mold is created based on the production plan, and information on the schedule is transmitted to the terminal for the mold producer. Based on the schedule information, the corresponding mold can be created according to the due date and delivered. Therefore, the user of the mold can receive delivery of the mold at an appropriate timing from the mold maker, and can reduce the excessive inventory of the mold.

The flowchart explaining the content of the process in the type | mold wear prediction apparatus and production management system in this Embodiment. The figure explaining the method of determining whether a type | mold exchange is required. The figure which expands and shows a part of shaping | molding die in a cross section. The figure explaining the node setting method.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 is a flowchart for explaining the contents of processing in the mold wear prediction apparatus and the production management system in the present embodiment.

  The wear prediction apparatus and the production management system using the wear prediction apparatus are configured by executing information processing by software using hardware, and as shown in FIG. 1, processes comprising steps 1 to 5. Is done. Steps 1 to 4 are performed by the information processing apparatus of the user who uses the mold, and step 5 is performed by the information processing apparatus (mold manufacturer terminal) of the mold manufacturer who manufactures the mold. The information processing apparatus is configured by hardware such as a computer terminal, for example.

  In step 1 (STEP 1), a mold wear amount prediction process for predicting a mold wear amount based on the use conditions of the mold is performed (a mold wear amount predicting unit). In step 2 (STEP 2), a post-mold wear shape prediction process for predicting the post-mold wear shape using the mold wear amount predicted in step 1 is performed (shape prediction means). In step 3 (STEP 3), work quality prediction processing is performed to predict the quality of the work manufactured by the mold based on the post-mold wear shape prediction process predicted in step 2 (work quality prediction). means).

  In step 4 (STEP 4), a replacement time prediction process for predicting a mold replacement time based on the work quality predicted in step 3, and a mold replacement based on the mold replacement time predicted by the process. A schedule plan creation process for creating a schedule for the schedule to be performed is performed (schedule plan creation means). In step 5 (STEP 5), a process for creating a production delivery plan for producing and delivering a mold based on the schedule plan created in step 4 is performed. In the mold wear prediction device, processing from step 1 to step 3 is performed, and in the production management system, processing from step 1 to step 5 is performed.

Next, specific processing contents in each step will be described.
In step 1, the production plan information including the usage conditions of the mold is input. Then, the die wear amount of the mold is predicted by the die wear amount prediction process, and the die wear amount distribution data (absolute value) of the product die is obtained from the predicted die wear amount.

  Various methods can be used as a method for predicting the mold wear amount of the mold. For example, in the present embodiment, a method described in Japanese Patent Laid-Open No. 2002-321032 that is already known is used. Predict. This known method is based on the use conditions of the mold, and calculates a wear amount calculation formula that is a function of a metallic load that is an aggressive factor for the mold and a thermal degradation strength that is a strength degradation factor for the mold. The die wear amount is calculated by calculation.

  In the die wear amount prediction process, a die wear amount for each preset lot is calculated. In the present embodiment, calculation is performed for each lot (for example, 1500 shots). The amount of die wear was the wear depth of the mold. The mold is composed of a plurality of molds such as an upper mold and a lower mold, and mold wear distribution data is obtained for each mold.

  In step 2, the die wear amount predicted in step 1 is transferred to the die wear shape to create a die wear shape distribution die model. The die wear shape distribution die model is a three-dimensional die model, and is created for each lot. The die model of each lot has a shape after die wear predicted using the die wear amount. The process for predicting the shape after mold wear will be described later.

  In step 3, molding analysis is performed using a mold model of a mold wear shape distribution, and workpiece quality data at the time of mold wear is calculated. Specifically, the shape of the work when the mold model of each mold is assembled and formed is obtained. Work quality data (work shape) is obtained for each lot.

  In step 4, it is determined whether or not the mold needs to be changed based on the work quality data when the mold is worn. Specifically, the work quality data of each lot is compared with a preset threshold value, and the earliest lot whose work quality data falls below the threshold value is determined first among the lots. Then, by referring to the production plan using the information on the earliest lot, the mold replacement date that is the replacement time of the mold is determined. The mold exchange date is determined for each type such as the upper mold and the lower mold, and a schedule plan for each mold exchange date is created.

  FIG. 2 is a diagram for explaining a method for determining whether or not mold exchange is necessary based on work quality data. The forming die is composed of a lower die 11 to 13 and an upper die 21, and the upper die 21 is brought close to the lower die 11 to 13, and the workpiece W is pressed between the lower die 11 to 13 and the upper die 21. To form a desired shape.

  As shown in FIG. 2 (a), in the state without mold wear (when the mold is new), by moving the upper side 21 downward to a preset position, the workpiece quality is within the standard. Work W (good product) can be formed.

  On the other hand, as shown in FIG. 2B, for example, in a state where the edge portion of the lower die 13 has been worn away after 1000 shots and there is die wear, the upper die 21 is moved downward to a preset position. In addition, due to the wear of the lower mold 13, more material is taken by the amount of wear.

  Accordingly, it is possible to determine that a lacking portion x occurs in the workpiece W, the workpiece quality does not satisfy the standard (defective product), and the lower mold 13 must be replaced. By simultaneously predicting the influence on the workpiece quality when the lower molds 11 and 12 are worn, the number of shots that need to be replaced can be determined.

  In step 5, a production plan for producing a mold is created based on a schedule plan for each type of mold replacement date. The schedule information on the mold exchange date is transmitted from the information processing terminal of the user to the information processing terminal for the mold producer (schedule plan information transmitting means). The information processing terminal for the mold maker determines the delivery date of the product mold based on the schedule information, and creates a plan for manufacturing the mold by calculating backward from the delivery date.

  In the present embodiment, the case where the process of creating the manufacturing plan is performed by the information processing terminal for the mold producer is described as an example. However, the present invention is not limited to this example. Information on the schedule may be transmitted to the information processing terminal for the mold maker by e-mail or the like, and a plan for the mold maker to produce the mold may be created based on the transmitted schedule information.

Next, the process for predicting the shape after mold wear in step 2 will be described in detail.
In the process of predicting the shape after mold wear, a plurality of nodes are set on the surface and inside of the mold, and a normal passing through the surface nodes set on the surface of the mold is selected from the set nodes. A process of calculating, moving the position of the surface node along the normal line in the wear direction by the amount of mold wear at the surface node, and predicting the shape after mold wear based on the position of the surface contact after the movement is performed.

FIG. 3 is an enlarged cross-sectional view of the edge portion formed on the mold surface of the mold.
As shown in FIG. 3, the edge 31 is a boundary portion between a facing surface 32 that faces the moving direction of the workpiece material (thick arrow A in the drawing) and a vertical wall surface 33 that extends along the moving direction of the workpiece material. Is formed. Surface nodes p are set at predetermined intervals on the mold surface s0 of the mold (new article) before wear. Then, each normal line n passing through each surface node p is calculated, and moved along the normal line n in the wear direction by the die wear amount for one lot at each surface node p.

  The shape obtained by joining the moved surface nodes p 'is predicted to be the shape after die wear of the die surface s1 after one lot. Then, each surface node p ′ of the mold surface s1 is moved in the wear direction by the amount of mold wear along each normal n, and the post-mold wear shape of the mold surface S2 after 2 lots is predicted. Similarly, each surface node p ″ of the mold surface s2 is moved in the wear direction by the amount of mold wear along each normal n, and the post-mold wear shape of the mold surface s3 after 3 lots is predicted. Thus, the movement of the nodes is performed step by step for each rod.

  In the state before wear (new article), the plurality of surface nodes p are set at a predetermined interval from the mold surface S0. However, as the number of lots increases, the plurality of surfaces located at the center of the edge portion. The nodes p are gradually spaced apart, and the plurality of surface nodes p located on the sides of the edge portion are gradually spaced.

  Then, by moving the surface node p, when at least a part of all the nodes is overlapped, a process for resetting all the nodes is performed.

  FIG. 4 is a diagram for explaining a node setting method. For example, as shown in FIG. 4A, a mesh M is set for the edge portion 41 of the mold before the mold wear, and a plurality of surface nodes p and internal nodes q are set based on the mesh M, respectively. The

  Then, as shown in FIG. 4B, each surface node p is moved in the wear direction by the die wear amount of one lot. By such movement of the surface node p, the plurality of surface nodes p set in the central region of the edge portion 41 are gradually spaced apart (see FIG. 3), and the surface node p becomes the internal node q. Due to the approach, a surface node p and another surface node p, or an overlapping portion (for example, Y portion in FIG. 4) where the nodes such as the surface node p and the internal node q overlap each other occurs. When an overlapping portion between nodes occurs, it is impossible to continue the calculation for moving the surface node p.

  Therefore, in this embodiment, when the occurrence of an overlapping portion is detected, the mesh M is cut again as shown in FIG. 4C, and all nodes p and q are reset. By this resetting, the nodes are rearranged at positions separated from each other by a predetermined distance, and the surface node p can be moved. As described above, the internal node movement method in which the balance position of the internal node q when the surface node p is forcibly moved in accordance with the amount of die wear and the cacobian of the tetra element does not become negative is the node of the present invention. It is used in the setting method (establishing a routine of simultaneous linear equations).

  According to the mold wear prediction apparatus of the present invention, the mold wear amount is predicted based on the usage conditions of the mold, and the post-mold wear shape is predicted using the predicted mold wear amount. The workpiece quality can be predicted based on the shape, and the mold replacement time can be predicted based on the workpiece quality. Therefore, for example, transition of the mold wear shape and work quality for each lot can be predicted, and the replacement time of the mold that causes the work quality to be inhibited can be determined.

  According to the production management system of the present invention, a schedule for exchanging the mold is created based on the production plan, and information on the schedule is transmitted to the information processing apparatus of the mold maker. Can create and deliver a corresponding mold according to the due date based on schedule information. Therefore, the user of the mold can receive the mold at an appropriate timing (just-in-time) from the mold maker, and can reduce excessive inventory of the mold.

  Therefore, for example, when the number of production lots is set based on the production plan presented at the beginning of the month, the mold wear shape at the time of one lot (for example, 1500 shots) is predicted, and thus the work quality and quality are adversely affected. It is possible to confirm the mold in which the wear is exerted. By performing this for one month when the production plan is presented, it becomes possible to confirm the work quality tendency and the mold wear at the date level, and it is possible to determine the mold replacement.

  Therefore, in the past, excessive mold inventory has been performed in order to cope with rapid mold replacement, and excessive inventory of workpieces has been a problem in order not to delay post-process supply due to poor quality due to mold wear. All these problems can be solved.

11, 12, 13 Lower mold 21 Upper mold 31 Edge 32 Opposite surface 33 Vertical wall surface n Normal line p Surface node q Internal nodes s0, s1, s2 Mold surface x Depleted portion W Workpiece

Claims (9)

A mold wear prediction device for predicting the wear state of a mold,
A mold wear amount prediction means for predicting a mold wear amount based on the use conditions of the mold; and
A shape prediction means for predicting the shape after mold wear using the mold wear amount predicted by the mold wear amount prediction means;
A mold wear prediction apparatus characterized by comprising: The shape prediction means includes
Setting a plurality of nodes on the surface and inside of the mold,
Among the plurality of set nodes, calculate a normal passing through the surface node set on the surface of the mold,
Moving the position of the surface node along the normal in the wear direction by the die wear amount at the surface node;
2. The mold wear prediction apparatus according to claim 1, wherein a shape after mold wear is predicted based on the position of the surface contact after the movement. The shape prediction means includes
3. The mold wear prediction apparatus according to claim 2, wherein after the surface nodes are moved, all nodes are reset when at least a part of all the nodes is overlapped. 4. The die wear amount prediction means predicts a die wear amount for each preset lot,
The mold wear prediction apparatus according to claim 3, wherein the shape predicting unit predicts a shape after mold wear of each lot based on the mold wear amount.   5. The work quality prediction means for predicting a work quality of a work manufactured by the forming die based on the shape after die wear predicted by the shape prediction means. 6. The mold wear prediction apparatus according to one item.   The mold wear prediction apparatus according to claim 5, further comprising a replacement time prediction unit that predicts a replacement time of the mold based on the work quality predicted by the work quality prediction unit.   The mold wear prediction apparatus according to claim 6, further comprising a schedule plan creation unit that creates a schedule of a schedule for replacing the mold based on the replacement period of the mold predicted by the replacement time prediction unit.   8. The mold wear prediction apparatus according to claim 7, further comprising schedule plan information transmitting means for transmitting schedule plan information created by the schedule plan creating means to a mold maker terminal. A production management system for managing the replacement time of a mold,
A mold wear amount prediction means for predicting a mold wear amount based on the use conditions of the mold; and
A shape prediction means for predicting the shape after mold wear using the mold wear amount predicted by the mold wear amount prediction means;
Workpiece quality prediction means for predicting the workpiece quality of the workpiece manufactured by the mold based on the shape after die wear predicted by the shape prediction means;
Replacement time prediction means for predicting the replacement time of the mold based on the work quality predicted by the work quality prediction means;
A schedule planning means for creating a schedule of schedules for replacing the mold based on the replacement time of the mold predicted by the replacement time prediction means;
A production management system comprising schedule plan information transmitting means for transmitting schedule plan information created by the schedule plan creating means to a terminal for a mold maker.

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