JP2019013976A - Forging press and its failure prediction method - Google Patents

Abstract

To predict a failure precisely by grasping an operation condition of a press body without installing newly a measuring instrument.SOLUTION: A forging press is provided with a press body 10 for lifting a slide 1 by rotatively driving a crank shaft, a plurality of sensors for detecting an operation condition of the press body 10, a programmable logic controller 40 for analyzing the operation condition based on information from the plurality of sensors, and a monitor 42 for graph displaying the analyzed operation condition. The programmable logic controller 40 analyzes information on change of the operation condition, and predicts a failure.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a forging press and a failure prediction method thereof, and more particularly to a forging press monitoring technique.

  2. Description of the Related Art Conventionally, a mechanical forging press that rotates a crankshaft and moves a slide up and down is known. Various abnormalities occur while using such a forging press, and the forging press may suddenly stop and production may stop. In such a case, it is necessary to prepare a measuring instrument or the like for the elucidation of the abnormal content, and it takes time to recover. In addition, the failure state could not be analyzed without checking the actual machine at the site. Furthermore, since the initial normal state of the forging press is unclear, it takes time to elucidate the cause of the failure.

  Therefore, for example, as in Patent Document 1, measuring means for measuring the operating state of an industrial machine, recording means for recording data measured by this measuring means as time-sequential waveform data, and the recorded data 2. Description of the Related Art An industrial machine monitor device having display means for processing waveform data and displaying graphics is known.

JP 2000-210800 A

  However, the invention of Patent Document 1 can perform a failure diagnosis when a failure occurs, but does not assume the prediction of the failure.

  The present invention has been made in view of the above points, and the object of the present invention is to grasp the operating status of the press body without newly installing a measuring instrument and to accurately predict failure. is there.

  In order to achieve the above object, in the present invention, the operation state of the press body is monitored from information obtained by a plurality of sensors.

Specifically, the forging press of the first invention is
A press body that rotates the crankshaft to move the slide up and down;
A plurality of sensors for detecting the operation status of the press body;
A programmable logic controller that analyzes the driving situation based on information of the plurality of sensors;
A monitor for displaying the analyzed driving situation in a graph;
The programmable logic controller analyzes information about the change in the driving situation and predicts a failure.

  According to the above configuration, the forging press has a plurality of sensors for detecting the operation status of the press main body. Therefore, if a plurality of sensors are provided at the beginning, the monitor can be provided without newly providing a plurality of sensors. You can easily understand the driving situation. Then, by monitoring the change in the operation status, it is possible to predict the failure of the press body from the regularity. Even if a failure occurs, it is possible to easily find an abnormal part by reviewing the measurement result, and to repair immediately and to restart the operation at an early stage.

In the second invention, in the first invention,
The programmable logic controller stores an initial normal state of the press body, and compares the initial normal state with the measured operating state to predict a failure.

  According to the above configuration, a failure can be predicted in light of past empirical rules by checking changes in the measurement results obtained from a plurality of sensors from the initial normal state on the monitor.

In the third invention, in the first or second invention,
The plurality of sensors include at least a load sensor for applying a load applied to the press body,
A burr cam for detecting the press angle of the press body,
The programmable logic controller monitors the relationship between the press angle and the value of the load sensor, and determines that it is abnormal when the relationship is out of range.

  According to the above configuration, by constantly monitoring the load transition, it is possible to detect an abnormality and perform failure prevention, product accuracy management, prediction of parts replacement timing, and the like.

In a fourth invention, in any one of the first to third inventions,
The plurality of sensors include a displacement sensor that detects at least the die height of the press body,
The programmable logic controller determines that there is an abnormality when the value of the displacement sensor is outside a preset range.

  According to the above configuration, by constantly monitoring, it is possible to easily and surely manage the die height, which is important for product accuracy management, to detect an abnormality and prevent a failure.

In a fifth invention, in any one of the first to fourth inventions,
The plurality of sensors include at least a varicam that detects a press angle of the press body,
A displacement sensor for detecting the position of the lower knockout device of the press body;
A displacement sensor for detecting the position of the upper knockout device of the press body,
The programmable logic controller monitors the relationship between the press angle, the position of the lower knockout device of the press body and the position of the upper knockout device, and determines that an abnormality occurs when the relationship is outside a preset range. To do.

  According to the above configuration, by constantly monitoring, it is possible to easily and reliably manage the press angle and the position of the vertical knockout device, which are important for product accuracy management, to detect abnormalities, prevent failures and maintain product accuracy. Can do.

In a sixth invention, in any one of the first to fifth inventions,
The plurality of sensors include a clutch pressure sensor that detects a pressure of a clutch of the press body, a clutch tank pressure sensor that detects a pressure of hydraulic oil that drives the clutch, and a brake slack that detects a slack pressure of a brake of the press body. Pressure sensor, brake tank pressure sensor for detecting the pressure of the cooling water of the brake, brake cooling water flow rate sensor for detecting the flow rate of cooling water of the brake, and air blow pressure for detecting the pressure of the high-pressure air supplied to the press body Sensor, resistance temperature detector for detecting the temperature of each part of the press body, mold lubrication flow rate sensor for detecting the flow rate of lubricating oil for lubricating the mold, and material temperature sensor for detecting the temperature of the material supplied to the press body Selected from the group consisting of
The programmable logic controller predicts a failure from the transition of information obtained by the selected plurality of sensors.

  According to the above configuration, it is possible to constantly monitor by obtaining information from sensors provided in advance, and to perform failure prevention, product accuracy management, prediction of parts replacement timing, and the like.

In a seventh invention, in any one of the first to sixth inventions,
A wireless communication device for connecting the programmable logic controller to a network through a public wireless communication line;
It is configured to perform at least failure prediction and product accuracy management of the press body from a maintenance terminal connected to the network.

  According to the above configuration, it is possible to monitor the press body from a remote location to prevent failure, manage product accuracy, and predict parts replacement time.

In the eighth invention,
Press body for rotating and driving the crankshaft to move the slide up and down, a plurality of sensors for detecting the operation state of the press body, and a programmable logic controller for analyzing the operation state based on information of the plurality of sensors And a preparation step of preparing a monitor for displaying the analyzed driving situation in a graph,
An initial state storing step in which the programmable logic controller analyzes and stores the initial normal state of the press body based on the information of the plurality of sensors, and
The programmable logic controller analyzes the plurality of sensors during operation of the press main body based on information, and displays an operation status display step for displaying changes in the operation status on the monitor,
A failure prediction step of predicting a failure by comparing the initial normal state and the measured operating state is adopted.

  According to the above configuration, if the forging press is first provided with a plurality of sensors for detecting the operation status of the press body, the operation status can be easily grasped by looking at the monitor without newly providing a plurality of sensors. . Then, by confirming changes in the measurement results obtained from the plurality of sensors from the initial normal state on the monitor, it is possible to predict a failure in light of past empirical rules. Even if a failure occurs, it is possible to easily find an abnormal part by reviewing the measurement result using a monitor, and to immediately repair the product by quickly repairing it.

  As described above, according to the present invention, a plurality of sensors for detecting the operation status of the press body are provided, and the programmable logic controller analyzes information on the change in the operation status and predicts a failure. As a result, it is possible to grasp the operation status of the press body without newly installing a measuring instrument and accurately predict failure.

It is a figure which shows the outline | summary of a structure of the forge press which concerns on embodiment of this invention. It is a figure which shows the outline | summary of a press main body and various sensors. It is the figure put together about each of a plurality of sensors. It is a figure which shows the example of a screen which shows the slide motion diagram of a monitor. It is a figure which shows the example of a screen of the temperature display graph of a monitor. It is a figure which shows the example of a screen of the load and energy display of a monitor.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

  FIG. 2 shows a forging press 11 according to an embodiment of the present invention, and the forging press 11 includes a press body 10 made of a mechanical hot forging press. For example, the press body 10 is provided such that a slide 1 to which a mold (not shown) is attached and a bolster 2 are vertically opposed to each other in the frame 3. The press main body 10 is configured such that the slide 1 connected to the crankshaft 4 that is rotationally driven by the connecting rod 5 moves up and down. A flywheel 8 that is rotationally driven by a belt 7 by a main motor 6 is connected to one end side of the crankshaft 4 via a clutch 9. A brake device 12 that stops the rotation of the crankshaft 4 and stops the slide 1 is attached to the crankshaft 4. The press main body 10 is forged by moving the flywheel 8 at a constant speed by the main motor 6 and forging the slide 1 up and down by transmitting the rotation of the flywheel 8 to the crankshaft 4 with the clutch 9 engaged. It is configured.

  The press main body 10 includes a plurality of sensors that detect operating conditions. The plurality of sensors will be described later. The press body 10 includes a PLC 40 as a programmable logic controller that analyzes an operation state based on information from a plurality of sensors. The PLC 40 is connected to a monitoring PC 42 as a monitor, and is configured to be able to display a graph of the operation status analyzed by the PLC 40 with the monitor of the monitoring PC 42.

  The press body 10 includes a wireless communication device 43 that connects the PLC 40 to the network 45 through a public wireless communication line. The maintenance terminal 46 connected to the network 45 through the Internet line 44 or the like is configured to perform at least failure prediction and product accuracy management of the press body 10.

  As shown in FIG. 2, various sensors are conceivable. In the present embodiment, for example, they are listed in FIG. For example, the plurality of sensors includes a load sensor 20 made of a strain gauge or the like that applies a load applied to the press body 10. The strain gauge is affixed to a necessary portion of the press body 10. For example, as shown in FIG. 1, the value of the load sensor 20 is collected by a load meter 20 a and sent to the PLC 40. A plurality of load sensors 20 may be provided. The press body 10 includes a varicam 21 that detects the press angle.

  The plurality of sensors include a brake slack pressure sensor 22 that detects the slack pressure of the brake device 12 of the press body 10, a clutch pressure sensor 23 that detects the pressure of the clutch 9 of the press body 10, and the pressure of the hydraulic oil that drives the clutch 9. A clutch tank pressure sensor 24 for detecting, a brake tank pressure sensor 25 for detecting the pressure of the cooling water of the brake device 12, a brake cooling water flow rate sensor 26 for detecting the flow rate of the cooling water of the brake device, and a temperature of each part of the press body 10 are detected. A temperature measuring resistor 29, a mold lubrication flow rate sensor 30 for detecting the flow rate of lubricating oil for lubricating the die, an air blow pressure sensor 31 for detecting the pressure of high-pressure air supplied to the press body 10, and a supply to the press body 10 And a material temperature sensor 32 for detecting the temperature of the material to be processed. All of these sensors need not be provided, and may be appropriately selected as necessary.

  The plurality of sensors includes a die height displacement sensor 33 that detects the die height of the press body 10. Further, the plurality of sensors includes a BKO position displacement sensor 27 that detects the position (BKO position) of the lower knockout device of the press body 10 and an SKO position displacement sensor 28 that detects the position (SKO position) of the upper knockout device. ing.

  As shown in FIG. 3, the plurality of sensors may include a light beam sensor 34 that counts the production amount, and includes a clutch engagement signal 35 for measuring the clutch operation time, and a brake engagement signal for measuring the brake operation time. 36 may be input to the PLC 40.

  Next, the operation of the PLC 40 in this embodiment will be described.

  First, forging press 11 provided with PLC40, various sensors, monitoring PC42, etc. is prepared as a preparation process. Further, although the forging press 11 is provided with a wireless communication device 43, this is not essential.

  Next, in the initial state storage step, the PLC 40 analyzes and stores the initial normal state of the press body 10 based on information from a plurality of sensors.

  Next, in the operation status display step, the PLC 40 analyzes a plurality of sensors during operation of the press body 10 based on the information, and displays changes in the operation status on the monitoring PC 42. For example, it is shown in FIGS.

  In the failure prediction step, the PLC 40 predicts a failure by comparing the initial normal state with the measured operation state. For example, when a failure is predicted, the fact is displayed on the monitoring PC 42. Thus, PLC40 preserve | saves the initial normal state of the press main body 10, and compares this initial normal state with the measured operating condition, and predicts a failure.

  For example, when the value of the load sensor 20 shown in FIG. 6 is outside the range set corresponding to each press angle, the PLC 40 determines that there is an abnormality. Further, the peak value of the load sensor 20 is set in advance, and if the value is exceeded, it is determined that there is an abnormality. As described above, in this embodiment, it is possible to perform failure prevention, product accuracy management, prediction of parts replacement timing, and the like by constantly monitoring the load transition.

  As shown in FIG. 4, regarding the signal from the brake slack pressure sensor 22, the time from the brake release signal to the rise of the slack pressure is monitored, and if it is not within a preset setting range, it is determined as abnormal. Also, the time from the brake close signal to the fall of the slack pressure is monitored, and if it is not within the preset setting range, it is determined that there is an abnormality.

  The clutch pressure sensor 23 is monitored from the clutch ON signal to the rise of the ON pressure, and if it is not within a preset setting range, it is determined as abnormal. Further, the period from the clutch OFF signal to the fall of the ON pressure is monitored, and if it is not within a preset setting range, it is determined that there is an abnormality.

  Regarding the clutch tank pressure sensor 24, the pressure transition is monitored, and if it is not higher than the set pressure, it is determined that there is an abnormality.

  The brake tank pressure sensor 25 also monitors the pressure transition, and determines that it is abnormal if it is not higher than the set pressure.

  The brake coolant flow sensor 26 monitors the flow rate transition, and determines that it is abnormal if it is not greater than the set amount.

  The PLC 40 monitors the values of the varicam 21 and the values of the BKO position displacement sensor 27 and the SKO position displacement sensor 28 shown in FIGS. 4 and 6, and determines that an abnormality is found when this relationship is outside the preset range. To do. In this embodiment, by constantly monitoring, it is possible to easily and surely manage the press angle and the position of the vertical knockout device, which are important for product accuracy management, and to perform failure prevention, product accuracy management, and the like.

  Further, as illustrated in FIG. 5, the PLC 40 receives a signal from the resistance temperature detector 29, displays the transition of each temperature on the monitoring PC 42, monitors the absolute temperature and the temperature gradient, and if it is not within the set range, it is abnormal. to decide.

  Further, the PLC 40 monitors the flow rate of the lubricating oil based on the signal sent from the mold lubrication flow rate sensor 30, and determines that it is abnormal if it is not within the set range.

  Further, the PLC 40 receives the value of the air blow pressure from the air blow pressure sensor 31, displays the value on the monitoring PC 42, and determines that it is abnormal if it is not within the set range.

  Further, the PLC 40 receives the value from the material temperature sensor 32, monitors the material temperature, and determines that it is abnormal if it is not within the set range.

  Although the monitor screen is not shown, the PLC 40 determines that the value is abnormal when the value of the die height displacement sensor 33 is outside the preset range. In this way, by constantly monitoring the die height, it is possible to easily and reliably manage the die height which is important for product accuracy management.

  Note that the PLC 40 may receive a signal from the light beam sensor 34 to monitor the production amount and display it on the monitoring PC 42. Failures can also be predicted from the change in production volume. The PLC 40 receives the clutch engagement signal 35 and the brake engagement signal 36, monitors the clutch operation time and the brake operation time, and determines whether there is an abnormality.

  As described above, when the PLC 40 analyzes the information on the change of the driving situation from the change of the information obtained by the plurality of selected sensors, and when there is an abnormality, it is determined that the operation will continue to cause a failure. May automatically stop or issue a warning.

  As described above, in this embodiment, it is possible to constantly monitor by obtaining information from a sensor provided in advance, and to perform failure prevention, product accuracy management, and part replacement time prediction.

  Further, in the present embodiment, the forging press 11 includes a plurality of sensors for detecting the operation status of the press main body 10, so that the operation status can be easily determined by looking at the monitoring PC 42 without newly providing a plurality of sensors. I can grasp. And by monitoring the change of the driving | running condition, the failure prediction of the press main body 10 can be performed from the regularity etc. of abnormality occurrence, for example. Even if a failure occurs, it is possible to easily find an abnormal part by reviewing the measurement result, and to repair immediately and to restart the operation at an early stage.

  In the present embodiment, the monitoring PC 42 confirms the change from the initial normal state of the measurement results obtained from a plurality of sensors, so that a failure can be predicted efficiently and reliably in light of past empirical rules. it can.

  Moreover, when the wireless communication device 43 is used, the press main body 10 is monitored from the maintenance terminal 46 connected to the network 45 through the Internet line 44 or the like, so that failure prevention and product accuracy management can be performed without going to the site. It is possible to predict the parts replacement time.

  Further, the administrator may visually check the monitoring PC 42 and prevent the failure or replace the parts before the PLC 40 predicts a failure from the change of each numerical value including the initial normal state.

  Even if a failure occurs, the PLC 40 stores the data of each sensor, and by analyzing it, the cause of the failure can be pursued easily and quickly. In addition, more accurate failure prevention may be performed using the data.

  Therefore, according to the forging press 11 according to the present embodiment, a plurality of sensors for detecting the operation status of the press body 10 are provided, and the PLC 40 analyzes information about changes in the operation status and predicts a failure. Thus, it is possible to grasp the operation status of the press body 10 without newly installing a measuring instrument and accurately predict a failure.

(Other embodiments)
The present invention may have the following configurations for the embodiments.

  That is, in the above-described embodiment, an example in which the press main body 10 includes various sensors in advance has been described, but various sensors and the like may be provided in an existing press main body. Once a plurality of sensors or the like are provided, failure prevention, product accuracy management, prediction of parts replacement timing, and the like can be performed without newly providing measurement equipment.

  In the above-described embodiment, the wireless communication device 43 is provided so that failure prediction or the like can be performed even in a remote place. However, the wireless communication device 43 or the like is not always necessary, and the network 45 does not pass through the wireless communication device 43. You may enable it to manage in the management room apart from the forging press 11, and you may enable it to manage several forging press 11 simultaneously. Further, the forging press 11 alone may be managed without being connected to the network 45 or the like.

  In addition, the above embodiment is an essentially preferable illustration, Comprising: It does not intend restrict | limiting the range of this invention, its application thing, or a use.

1 slide
2 Bolster
3 frames
4 Crankshaft
5 Connecting rod
6 Main motor
7 Belt
8 Flywheel
9 Clutch
10 Press body
11 Forging press
12 Brake device
20 Load sensor
20a load cell
21 Varicam
22 Brake slack pressure sensor
23 Clutch pressure sensor
24 Clutch tank pressure sensor
25 Brake tank pressure sensor
26 Brake coolant flow sensor
27 BKO position displacement sensor
28 SKO position displacement sensor
29 RTD
30 Mold lubrication flow sensor
31 Air blow pressure sensor
32 Material temperature sensor
33 Die height displacement sensor
34 Light sensor
35 Clutch engagement signal
36 Brake input signal
40 PLC (Programmable Logic Controller)
42 Monitoring PC (Monitor)
43 Wireless communication device
44 Internet access
45 network
46 Maintenance terminal

Claims (8)

A press body that rotates the crankshaft to move the slide up and down;
A plurality of sensors for detecting the operation status of the press body;
A programmable logic controller that analyzes the driving situation based on information of the plurality of sensors;
A monitor for displaying the analyzed driving situation in a graph;
The forging press characterized in that the programmable logic controller analyzes information on the change in the operating condition and predicts a failure. The forging press according to claim 1,
The forging press characterized in that the programmable logic controller stores an initial normal state of the press main body and compares the initial normal state with the measured operation state to predict a failure. In the forging press according to claim 1 or 2,
The plurality of sensors include at least a load sensor for applying a load applied to the press body,
A burr cam for detecting the press angle of the press body,
The forging press, wherein the programmable logic controller monitors a relationship between the press angle and the value of the load sensor, and determines that the relationship is abnormal when the relationship is out of range. In the forging press according to any one of claims 1 to 3,
The plurality of sensors include a displacement sensor that detects at least the die height of the press body,
The forging press, wherein the programmable logic controller determines that the value of the displacement sensor is abnormal when the value is outside a preset range. The forging press according to any one of claims 1 to 4,
The plurality of sensors include at least a varicam that detects a press angle of the press body,
A displacement sensor for detecting the position of the lower knockout device of the press body;
A displacement sensor for detecting the position of the upper knockout device of the press body,
The programmable logic controller monitors the relationship between the press angle, the position of the lower knockout device of the press body and the position of the upper knockout device, and determines that an abnormality occurs when the relationship is outside a preset range. A forging press characterized by In the forging press according to any one of claims 1 to 5,
The plurality of sensors include a clutch pressure sensor that detects a pressure of a clutch of the press body, a clutch tank pressure sensor that detects a pressure of hydraulic oil that drives the clutch, and a brake slack that detects a slack pressure of a brake of the press body. Pressure sensor, brake tank pressure sensor for detecting the pressure of the cooling water of the brake, brake cooling water flow rate sensor for detecting the flow rate of cooling water of the brake, and air blow pressure for detecting the pressure of the high-pressure air supplied to the press body Sensor, resistance temperature detector for detecting the temperature of each part of the press body, mold lubrication flow rate sensor for detecting the flow rate of lubricating oil for lubricating the mold, and material temperature sensor for detecting the temperature of the material supplied to the press body Selected from the group consisting of
The forging press, wherein the programmable logic controller predicts a failure from a transition of information obtained by the plurality of selected sensors. The forging press according to any one of claims 1 to 6,
A wireless communication device for connecting the programmable logic controller to a network through a public wireless communication line;
A forging press characterized in that it is configured to perform at least failure prediction of the press body and product accuracy pipe from a maintenance terminal connected to the network. Press body for rotating and driving the crankshaft to move the slide up and down, a plurality of sensors for detecting the operation state of the press body, and a programmable logic controller for analyzing the operation state based on information of the plurality of sensors And a preparation step of preparing a monitor for displaying the analyzed driving situation in a graph,
An initial state storing step in which the programmable logic controller analyzes and stores the initial normal state of the press body based on the information of the plurality of sensors, and
The programmable logic controller analyzes the plurality of sensors during operation of the press main body based on information, and displays an operation status display step for displaying changes in the operation status on the monitor,
A failure prediction method for a forging press, comprising: a failure prediction step of predicting a failure by comparing the initial normal state and the measured operating state.