JP5785700B2 - Bending system and method - Google Patents

Description

  The present invention relates to a bending system and a method thereof, and more particularly to a bending system and a method thereof that have a function of correcting a deviation of a workpiece from a gripping means in a bending machine and reduce processing defects of a product.

  Conventionally, the robot body of a bending robot grips the product to be processed (for example, a sheet metal) and approaches a plurality of molds attached to a bender (bending machine, etc.) to perform bending. There is no correction function.

  23 to 29 show a conventional bending method. First, as shown in FIG. 23, in a series of bending processes, if a deviation occurs when the workpiece (material) W loaded with the robot is gripped, the bending process is performed while the workpiece W is displaced. Crack bending failure occurs. Further, if a deviation occurs when the gripping means (gripper) changes the grip of the workpiece W, bending work is performed by a bending operation while the workpiece W is displaced, and a bending failure occurs. Further, if a deviation occurs between the workpiece W and the gripping means (gripper) due to the bending operation, bending work is performed by the bending operation while the workpiece W is displaced, and a bending failure occurs.

  Description will be made assuming a specific case. As shown in FIG. 24, the robot grips a workpiece W loaded on the loading carriage 37 and having a deviation. Then, when the workpiece W is brought into contact with the back gauges 17L and 17R as shown in FIG. 25 and abutting operation (gauge) is performed, the workpiece W, the punch die 11b, and the die die 15 are parallel as shown in FIG. However, in the X-axis direction, which is the left-right direction in the figure, a deviation occurs between the bending location and the mold position, and a product defect occurs due to the bending process by the bending operation.

  On the other hand, as shown in FIG. 27, it is assumed that the workpiece W is inclined with respect to the axis of the gripping means (gripper) 5 by bending. When the width of the workpiece W is small and only one place is bent, the workpiece W is likely to be displaced in the rotational direction after bending. When the position is displaced as shown in FIG. 28 and the work W is brought into contact with the back gauges 17L and 17R to perform the abutting operation (gauge), the work W, the punch die, and the die metal as shown in FIG. Although the molds are parallel, in the X-axis direction, which is the left-right direction in the figure, a deviation occurs between the bent portion and the punch die position, and a product defect occurs due to bending by the bending operation.

  See also Patent Documents 1 and 2.

JP-A-8-39151 JP 2006-218542 A

  There are the following problems. When the position shift occurs, there is a problem that a large number of defective products are generated if it is not noticed as it is.

  The invention of the present application reduces the occurrence of defective products due to a shift in the gripping position before bending, during bending, or after bending when the material (sheet metal) is gripped and automatically operated by a bending robot.

The present invention is for solving the above-mentioned problems. The invention according to claim 1 is a bending system comprising a gripping means for gripping a workpiece and a bending machine for bending the workpiece. When there is a deviation in the positional relationship between the gripping means and the workpiece by the time the machining is finished, a detection means for detecting the deviation and a correction for correcting the deviation according to the detection result of the detection means And the detecting means is a back gauge provided in the bending machine, and measures a displacement amount of the back gauge generated when the gripping means grips the workpiece and abuts against the back gauge. and, detecting the presence of the deviation in accordance with the measurement result, the correction means, when the deviation is detected by the detecting means, the workpiece is rotated 90 ° of the workpiece After the move to the abutted thereby to mold a position parallel to the back gauge, so that the distance of the gripping means to the mold with a parallel to the workpiece is the correct position, the by the gripping means work It is characterized by grasping.

The invention according to claim 2 is characterized in that the workpiece is loaded on a loading table, and the detection of the deviation by the detecting means is performed immediately after the workpiece is gripped and loaded from the loading table.

The invention according to claim 3 is characterized in that when the workpiece is subjected to bending in a plurality of steps, the detection by the detecting means is performed immediately after each bending.

The invention according to claim 4 is a bending method comprising a gripping means for gripping a workpiece and a bending machine for bending the workpiece. A detection step of detecting the presence of the shift when there is a shift in the positional relationship with the work, and a correction step of correcting the shift according to a detection result of the detection unit by a correction unit, The detection means is a back gauge provided in the bending machine, measures the amount of displacement of the back gauge generated when the gripping means grips the workpiece and abuts against the back gauge, and the measurement result in response to detecting the presence of said displacement, it said correction means, the case where the deviation is detected by the detecting means, wherein an edge of the workpiece the workpiece is rotated 90 ° back gate After is brought into contact with di moved to the mold position parallel such that said distance of the gripping means to the mold with a parallel to the workpiece is correct position, changing grasping the workpiece by the gripping means It is characterized by that.

  According to the present invention, for example, the value of the abutment sensor (for example, two back gauges) is read, and when the value of the abutment sensor exceeds a specified value, it is determined that there is a deviation between the gripping means and the workpiece. In addition, since the deviation is corrected, the occurrence of defective products can be suppressed, and the non-defective product can be processed.

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  1-3 show an example of a bending system 1 for bending a sheet metal part installed inside a work station. 1 to 3, as indicated by the coordinate axis Dim, the direction of the die holder 13 of the bending machine 3 is defined as the X-axis direction, the front-rear direction of the bending machine 3 is defined as the Y-axis perpendicular to the X-axis, A direction perpendicular to the flat surface (vertical direction of the bending machine 3) is taken as the Z-axis direction. Further, the axis in the rotation direction of the gripping means 5 provided in the robot arm 7 is defined as an A rotation axis (see FIG. 4 and the like).

  As shown in FIG. 1, the bending system 1 includes the following mechanical configuration. That is, a bending machine (press brake) 3 for bending the workpiece W, and five degrees of freedom (XYZ axis, A rotation axis, and the like) for operating and positioning the workpiece W in the bending machine (press brake) 3. To carry the robot arm 7 and gripping means (gripper) 5 for gripping operation, etc., and to load and position the raw workpiece W at a position where the robot arm 7 and gripping means (gripper) 5 grip, and to carry out the finished workpiece W The material loader / unloader (L / UL) 19 and the repositioning gripper (repositioning gripper) 5A for holding the workpiece W while the gripping means (gripper) 5 changes its gripping. The material loader / unloader (L / UL) 19 includes several suction disks that generate an upward suction force for lifting the workpiece W, and includes a handling robot having a traveling axis in the X-axis direction as a specific example. . As a result, the material loader / unloader (L / UL) 19 delivers the workpiece W to the gripping means (gripper) 5 provided at the tip of the robot arm 7, and then collects the workpiece W from the gripping means (gripper) 5. The completed work W can be carried out.

  FIG. 2 is a part view of the bending machine (press brake) 3 positioned to perform bending on the workpiece W. FIG. The parts include punch dies 11 a and 11 b held by a punch holder 9 that processes a workpiece W in cooperation with a robot arm 7 having a gripping means (gripper) 5, and a die mold installed in a die holder 13. Molds 15a, 15b, etc. are included. The back gauge mechanism 17 is shown in the vicinity of the punch die 11a and the die die 15a in FIG. 1, but the back gauge mechanism 17 is configured to be movable and positionable in the XYZ axial directions under the control of a bending machine / controller 21. Yes.

  Please refer to FIG. The stage (stage) 1 includes a stage at the leftmost part of the bending machine (press brake) 3, and the stage 2 is positioned on the right side of the stage 1 along the die holder 13. In FIG. 3, the stage 3 and subsequent stages are set although not shown.

  For example, when the first bending is performed in the stage 1, the workpiece W gripped by the gripping means (gripper) 5 moves to the stage 1 (at this time, the back gauge mechanism 17 having two back gauges 17L and 17R is also a stage. 2), the workpiece W is moved until it reaches and contacts the rear stop portions of the back gauges 17L and 17R of the back gauge mechanism 17, as shown in FIG. Next, bending is performed on the workpiece W at the stage 1. In the execution of the bending process, the die mold 15a moves upward in the Z-axis direction shown in FIG. When the punch die 11a and the die die 15a simultaneously contact the workpiece W so that the workpiece W takes a relatively stable posture in the bending machine (press brake) 3, the gripping means (gripper) 5 The gripping means (gripper) 5 is moved away from the workpiece W by moving the robot arm 7. Next, the bending machine (press brake) 3 completes the bending of the workpiece W by completing the upward movement of the die mold 15a until an appropriate bending is formed.

  During the bending process, the bending machine (press brake) 3 is lowered when the die mold 15a is temporarily engaged (engaged) with the punch mold 11a while holding the workpiece W in the bent state. The robot arm 7 repositions its gripping means (gripper) 5 in order to hold the workpiece W before the die mold 15a is disengaged (released). When the gripping means (gripper) 5 holds the workpiece W, it is disengaged by opening the die mold 15a. The robot arm 7 then moves the workpiece W and positions it again in order to perform the next bending with a specific bending sequence (bending order) programmed on the workpiece W. The next bend in the bend sequence is performed on the same stage 1 or different stages such as stages 2, 3 etc., depending on the type of bending performed and the mold set in the bending machine (press brake) 3. .

  Note that the gripping position of the gripping means (gripper) 5 needs to be repositioned according to the next bending to be performed and the shape of the workpiece W. The repositioning gripper 5A shown in FIG. 1 is provided for repositioning without holding the workpiece W in its bent state and without depending on the method in which the die mold 15a is once engaged with the punch mold 11a. ing. The workpiece W is moved to the repositioning gripper 5 </ b> A by the robot arm 7 before execution of the next bending that requires repositioning of the gripping means (gripper) 5. Next, the repositioning gripper 5A grips the workpiece W so that the gripping means (gripper) 5 can grip the workpiece W at a suitable position for the next bending or series of bending.

  The bending system 1 shown in FIG. 1 is controlled by a control device. These control devices include a bending machine / controller 21, a robot controller 23, and a loading / unloading controller 25. Each of these controllers is configured by a computer [including a PLC (Programmable Logic Controller) and the like], and includes a CPU (Central Processing Unit), a RAM (Random Access Memory), a ROM (Read Only Memory) storage device, and the like. It is operated by a computer program.

  The bending machine / controller 21 controls the bending machine 3, and the robot controller 23 controls the operation of the robot having the robot arm 7 and the gripping means (gripper) 5. The loading / unloading controller 25 controls the material loader / unloader (L / UL) 19 to carry in and out the workpiece W.

  The bending machine / controller 21, the robot controller 23, and the loading / unloading controller 25 are connected to each other so as to communicate with each other and operate in cooperation with each other.

  Further, the bending machine / controller 21 includes a bending control means 27 and a deviation detecting means 29, and the robot controller 23 includes a handling control means 31, an abutment control means 33, and a deviation correction means 35.

  The bending control unit 27 controls the bending operation and the like in the bending machine 3. The deviation detection means 29 includes two back gauges 17L and 17R, and is configured to measure the amount of movement and the like when the workpiece W contacts the back gauges 17L and 17R. The handling control means 31 controls the operation of the gripping means (gripper) 5 and the robot arm 7. The abutting control means 33 controls the gauging operation and the like of the gripping means (gripper) 5 that grips the workpiece W. The deviation correction unit 35 performs control to correct a deviation of the position existing between the workpiece W and the holding unit 5 by re-holding the workpiece W.

  The abutting operation (gauge) will be described with reference to FIGS. The abutting operation (gauging) is to position the workpiece W while alternately abutting the workpiece W gripped by the gripping means (gripper) 5 against the back gauges 17L and 17R in the A-axis rotation direction. That is, as shown in FIG. 4, the workpiece W is abutted against the back gauges 17L and 17R, and the workpiece W is rotated in one rotation direction. As a result, the angle Ang1 between the workpiece W and the die mold 15 becomes larger than 90 ° by several degrees. Thereafter, as shown in FIG. 5, the workpiece W is abutted against the back gauges 17L and 17R, and the workpiece W is rotated in the other rotation direction. As a result, the angle Ang2 between the workpiece W and the die mold 15 is smaller than 90 ° by several degrees. By repeating such an operation, the workpiece W becomes parallel to the back gauges 17L and 17R and the angle Ang3 between the die mold 15 and the workpiece W becomes approximately 90 ° as shown in FIG.

  FIG. 7 shows the structure of the back gauge mechanism 7. The back gauge mechanism 17 includes back gauges 17L and 17R including functions as at least two potentiometers in order to perform an abutting operation (gauge). Several methods are already known for determining the position and the amount of change in position, and so a detailed description is omitted, but an example is shown.

  The back gauge 17L has a measuring part 17La, a cylindrical mandrel part 17Lb, and a contact part 17Lc, and a spring member 17Ld is fitted around the mandrel part 17Lb. When the workpiece W comes into contact with the contact portion 17Lc, the spring member 17Ld contracts and the contact portion 17Lc and the mandrel portion 17Lb move. The measurement unit 17La electrically measures the movement position, the displacement amount, and the like based on the movement (for example, a displacement of about 15 mm can be measured).

  The back gauge 17R includes a measuring part 17Ra, a cylindrical mandrel part 17Rb, and a contact part 17Rc, and a spring member 17Rd is fitted around the mandrel part 17Rb. When the workpiece W comes into contact with the contact portion 17Rc, the spring member 17Rd contracts and the contact portion 17Rc and the mandrel portion 17Rb move. The measurement unit 17Ra electrically measures the movement position, the displacement amount, and the like based on the movement.

  Thereby, for example, the distance Dis1 can be obtained by the back gauge 17L, and the distance Dis2 can be obtained by the back gauge 17R. Furthermore, by detecting the shift of the workpiece W from the difference between the distance Dis1 and the distance Dis2, it is possible to detect that the angle Ang4 of the workpiece W is larger than 90 °.

  FIG. 8 shows the operation of the bending system 1. First, in step S01, the material loader / unloader (L / UL) 19 is controlled by the loading / unloading controller 25 to perform the loading process of the workpiece W. Then, the workpiece W to be bent is gripped by gripping means (gripper) 5 provided in the robot arm 7. Next, the workpiece W is approached between bending dies (die die, punch die).

  In step S03, the abutting control means 33 controls the gripping means (gripper) 5 to perform the abutting process. That is, in order to bend the workpiece W, it abuts against the back gauges 17L and 17R which are two potentiometers (gauge).

  In step S05, the deviation detection means 29 performs a deviation detection process. The movement positions and displacement amounts of the back gauges 17L and 17R are measured and calculated.

  In step S07, it is determined whether or not the blur detection means 29 is within the allowable value range. If it is an allowable value, the process proceeds to step S11. If it is determined that the value is not within the allowable value range, the process proceeds to step S09.

  In step S <b> 09, a deviation correction process is performed by the gripping means (gripper) 5 controlled by the deviation correction means 35. That is, the posture of the gripped work W is shaken by 90 °. Then, the die mold and punch mold are approached again. In order to correct the gripping position, it abuts against the back gauges 17L, 17R. The robot holding the workpiece W collimates the workpiece W and the mold while confirming the sensor value. When the parallelism is confirmed, the work W is sandwiched between a die die and a punch die. The gripping means (gripper) 5 releases the clamp of the workpiece W, makes the gripping means (gripper) 5 parallel to the workpiece W, corrects the distance to the mold to the correct position, and performs gripping. Then, the posture shaken by 90 ° is restored.

  Next, the workpiece W is approached between bending dies (die die, punch die), and abutting process is performed. And it abuts against the back gauges 17L, 17R. A displacement detection process is performed, and the displacement amounts of the back gauges 17L and 17R are measured. Then, the gripping means 5 that grips the workpiece W performs gauging to further parallel the workpiece W while confirming the measurement value of the sensor. Thereafter, the work W is sandwiched between molds and the gripping means (gripper) 5 is released from the work W.

  In step S <b> 11, the bending process is performed on the workpiece W by the bending machine 3 controlled by the bending control unit 27.

  In step S13, it is determined whether or not the bending control means 27 has been completed for all the bendings. If it is determined that the process has been completed, the process proceeds to step S17. If it is determined that all the bendings are not completed, the process proceeds to step S15.

  In step S15, handling processing is performed by the gripping means (gripper) 5 under the control of the handling control means 31, and then the process returns to step S03.

  In step S17, the material loader / unloader (L / UL) 19 is controlled by the loading / unloading controller 25 to perform the unloading process of the workpiece W.

  As described above, an operation for performing general deviation correction has been described, but a specific example will be described. Reference is made to FIGS. It is assumed that the workpiece W is loaded on the loading cart 37 by the material loader / unloader (L / UL) 19. As shown in FIG. 9, the loading position of the workpiece W is shifted with respect to the loading carriage 19. Here, it is assumed that the workpiece W is a plate material having a predetermined thickness and the outer shape is substantially rectangular.

  Please refer to FIG. Since the gripping means (gripper) 5 moves perpendicularly to the loading carriage 37 when gripping the workpiece W, when the workpiece W is gripped, the workpiece W is inclined with respect to the gripping means (gripper) 5. Then, it goes straight to the back gauges 17L, 17R and comes into contact therewith. Here, since the workpiece W is tilted and abuts against the back gauges 17L and 17R, the movement amounts of the abutting portions 17Lc and 17Rc are different. Then, when a predetermined difference (for example, 0.1 mm) occurs in the movement amount, it is determined to perform correction.

  Please refer to FIG. The gripping means (gripper) 5 of the robot arm 7 moves to another stage while gripping the workpiece W, rotates the workpiece W by 90 °, and brings the edge of the workpiece W into contact with the back gauges 17L and 17R.

  Please refer to FIG. The workpiece W is positioned in parallel to the die mold 15a by abutment operation (gauge). For this reason, the axis of the gripping means (gripper) 5 is inclined not diagonally to the die mold 15a. Then, the positions of the back gauges 17L and 17R (for example, the contact portions 17Lc and 17Rc) in this state are stored in a storage device or the like.

  Please refer to FIG. The workpiece W is lightly gripped (pressure that does not deform the workpiece W) in cooperation with the punch die 11a corresponding to the die die 15a.

  Refer to FIG. The gripping means (gripper) 5 once releases the grip on the workpiece W, then corrects the posture inclined obliquely with respect to the workpiece W so that the axis is perpendicular to the workpiece W, and grips the workpiece W again. To do. When gripping the workpiece W again, the outer shape of the workpiece W can be obtained from machining data, the position of the workpiece W is obtained by gauging operation, and the position of the gripping means (gripper) 5 is obtained from control data or the like. Therefore, the dimension a (the center of the workpiece W) is determined, the dimension b is provisionally determined, and the gripping means (gripper) 5 may perform gripping.

  Refer to FIG. The gripping means (gripper) 5 of the robot arm 7 rotates the workpiece W by 90 °, changes the stage, and returns the workpiece W to its original state. Thereafter, the back gauges 17L and 17R are brought into contact with each other, the position in the Y-axis direction is determined, and the workpiece W is bent by the cooperation of the die die 11a and the punch die 11b. Here, since the size and the bending position of the workpiece W are known, the dimension b is corrected by determining the stop position of the workpiece W in the Y-axis direction according to the displacement positions of the back gauges 17L and 17R.

  Reference is made to FIGS. It is assumed that the workpiece W is tilted with respect to the axis of the gripping means (gripper) 5 by bending, or tilted when gripping is changed. As shown in FIG. 16, when the width is small with respect to the workpiece W and only one place is bent, the workpiece W is easy to rotate after bending. For this reason, it is necessary to correct when the position is shifted. The workpiece W is a plate material having a predetermined thickness, and the outer shape is substantially rectangular.

  Since the robot arm 7 and the gripping means (gripper) 5 move vertically with respect to the workpiece position assumed to be normal when gripping the workpiece W, when the tilted workpiece W is gripped, the workpiece W is gripping means ( The gripper is inclined with respect to 5.

  Refer to FIG. It goes straight to the back gauges 17L and 17R and comes into contact therewith. Here, since the workpiece W is tilted and abuts against the back gauges 17L and 17R, the movement amounts of the abutting portions 17Lc and 17Rc are different. Then, when a predetermined difference (for example, 0.1 mm) occurs in the movement amount, it is determined to perform correction.

  Please refer to FIG. The gripping means (gripper) 5 of the robot arm 7 moves to another stage while gripping the workpiece W, rotates the workpiece W by 90 °, and brings the edge of the workpiece W into contact with the back gauges 17L and 17R.

  Refer to FIG. The workpiece W is made parallel to the die mold 15a by abutment operation (gauge). For this reason, the axis of the gripping means (gripper) 5 is inclined not diagonally to the die mold 15a.

  Refer to FIG. The workpiece W is lightly gripped (pressure that does not deform the workpiece W) in cooperation with the punch die 11a corresponding to the die die 15a.

  Refer to FIG. The gripping means (gripper) 5 once releases the grip on the workpiece W, then corrects the posture inclined obliquely with respect to the workpiece W so that the axis is perpendicular to the workpiece W, and grips the workpiece W again. To do. When gripping the workpiece W again, the outer shape of the workpiece W can be obtained from machining data, the position of the workpiece W is obtained by gauging operation, and the position of the gripping means (gripper) 5 is obtained from control data or the like. Therefore, the dimension a is determined, the dimension b (the center of the workpiece W) is provisionally determined, and the gripping means (gripper) 5 performs gripping.

  Refer to FIG. The gripping means (gripper) 5 of the robot arm 7 rotates the workpiece W by 90 °, changes the stage, and returns the workpiece W to its original state. Thereafter, the workpiece W is positioned by a gauging operation, and the workpiece W is bent by the cooperation of the die die 11a and the punch die 11b.

  Here, the correction value of the dimension b can be set to an accurate value because the workpiece position in the Y-axis direction can be specified by the gauging operation. Furthermore, there is a case where the gripping is performed again at the regular gripping position.

  The present invention is not limited to the embodiments of the invention described above, and can be implemented in other modes by making appropriate modifications.

1 Bending system 3 Bending machine (press brake)
5 Gripping means 5A Repositioning gripper 7 Robot arm 9 Punch holder 11a Punch die 11b Punch die 13 Die holder 15a Die die 15b Die die 17 Abutting means (back gauge)
19 Loader / Unloader 21 Bending Machine Controller 23 Robot Controller 25 Loading / Unloading Controller 27 Bending Control Unit 29 Deviation Detection Unit 31 Handling Control Unit 33 Abutting Control Unit 35 Deviation Correction Unit W Work Dim Coordinate Axis

Claims (4)

In a bending system comprising a gripping means for gripping a workpiece and a bending machine for bending the workpiece,
Detecting means for detecting the deviation when there is a deviation in the positional relationship between the gripping means and the workpiece before the completion of the predetermined processing;
Correction means for correcting the deviation according to the detection result of the detection means,
The detection means is a back gauge provided in the bending machine, and measures the displacement amount of the back gauge generated when the gripping means grips the workpiece and abuts against the back gauge. And detecting the presence of the deviation according to
When the deviation is detected by the detection unit , the correction unit rotates the workpiece by 90 °, contacts the back gauge with the edge of the workpiece, and moves the workpiece to a position parallel to the mold. A bending system characterized by gripping the workpiece by the gripping means so that the gripping means is parallel to the workpiece and the distance to the mold is in a correct position.   The bending work system according to claim 1, wherein the workpiece is loaded on a loading table, and the detection of the deviation by the detection unit is performed immediately after the workpiece is gripped and loaded from the loading table.   3. The bending system according to claim 1, wherein when the workpiece is subjected to a plurality of bending processes, the detection of the deviation by the detecting unit is performed immediately after each bending process. In a bending method comprising a gripping means for gripping a workpiece and a bending machine for bending the workpiece,
A detection step of detecting the presence of a deviation when a deviation exists in the positional relationship between the gripping means and the workpiece by the detection means until the predetermined processing is completed;
A correction step of correcting the deviation according to a detection result of the detection unit by a correction unit,
The detection means is a back gauge provided in the bending machine, and measures the displacement amount of the back gauge generated when the gripping means grips the workpiece and abuts against the back gauge. And detecting the presence of the deviation according to
When the deviation is detected by the detection unit , the correction unit rotates the workpiece by 90 °, contacts the back gauge with the edge of the workpiece, and moves the workpiece to a position parallel to the mold. A bending method characterized by gripping the workpiece by the gripping means so that the gripping means is parallel to the workpiece and the distance to the mold is in a correct position.

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