JP7021436B2 - Structure manufacturing method - Google Patents

Description

The present invention relates to a method for manufacturing a structure.

Patent Document 1 discloses a resin panel in which a core material is sandwiched between a pair of resin sheets.

Japanese Unexamined Patent Publication No. 2014-79001

In Patent Document 1, a resin panel is molded with a mold having a pinch-off portion surrounding the cavity, and a resin sheet located outside the pinch-off portion is a burr to be removed.

Such burrs are separated from the resin panel on the holding table and put into a crusher for recycling.

It is not easy to smoothly link such a series of operations.

The present invention has been made in view of such circumstances, and provides a method for manufacturing a structure, which enables the steps from molding to burr discharge to be smoothly interlocked.

According to the present invention, a method for manufacturing a structure includes a molding step, a holding step, a separating step, and a discharging step. In the molding step, a molded body is formed, and in the holding step, a holding table is provided. The molded body is held on a holding table in a state where the holding surface of the molded body is erected, and the molded body is configured by connecting the molded body body and burrs. Is separated, the burr is left on the holding table, and in the discharging step, a method is provided in which the burr placed on the holding table is discharged toward the burr receiver by tilting the holding table. ..

In the present invention, as described above, the molding step, the holding step, the separation step, and the discharging step are performed, so that the steps from molding to burr discharge can be smoothly interlocked.

Hereinafter, various embodiments of the present invention will be illustrated.
Preferably, the method described above is a method in which the holding step, the separating step, and the discharging step are carried out on the same straight line.
Preferably, in the method described above, the holding table is supported by a rotation mechanism rotatably configured around the first rotation axis, and during the transition from the holding step to the separation step, the holding table is supported. And the method in which the holding table is rotated by the rotation mechanism at the time of transition from the separation step to the discharge step.
Preferably, in the method described above, the rotation mechanism is configured to be movable along a transport line extending perpendicular to the first rotation axis, and is configured between the holding step and the discharging step. A method in which the rotating mechanism is moved along the transport line.

1A is a perspective view of the resin panel 1, and FIG. 1B is a perspective view of the core material 3. 2A is an exploded perspective view of the core material 3, FIG. 2B is an enlarged view of a region B in FIG. 2A, and FIG. 2C is an end view of the reinforcing member 3c. It is a top view of the manufacturing system 20. It is an enlarged view near the member supply line 7 of the manufacturing system 20. 5A to 5B are a sectional view taken along the line AA and a sectional view taken along the line BB in FIG. 4, respectively. It is a figure corresponding to FIG. 4 for demonstrating the operation of the core material transfer table 22 and the skin material transfer table 23. 7A is a perspective view of the head 24 of the manipulator 5, and FIGS. 7B to 7C are enlarged views of a region B and a region C in FIG. 7A, respectively. It is a perspective view of the state in which the core material 3 is adsorbed on the head 24. FIG. 9A shows a state in which the positioning table 8a of the positioning device 8 is horizontal, and FIG. 9B shows a state in which the positioning table 8a is tilted. 10A is a perspective view for explaining a substrate position correction step, and FIG. 10B is an enlarged view of a region B in FIG. 10A. 11A is a perspective view for explaining a reinforcing member position correction step, and FIGS. 11B to 11C are enlarged views of a region B and a region C in FIG. 11A, respectively. 12A is a perspective view of the insertion device 9, and FIG. 12B is an enlarged view of the region B in FIG. 12A. It is a perspective view of the state in which the core material 3 is adsorbed on the insertion device 9. It is a perspective view for demonstrating the skin material positioning process. FIG. 15A is a perspective view showing a state in which the skin material 4 is held by the head 24, and FIG. 15B is an enlarged view of a region B in FIG. 15A. 16A is a perspective view for explaining a process of passing the skin material 4 from the head 24 to the insertion device 9, and FIG. 16B is an enlarged view of a region B in FIG. 16A. 17A to 17E are front views for explaining a process of passing the skin material 4 from the male mold holding portion 24d to the female mold holding portion 9c. It is a front view which shows the structure of the molding machine 10 (the molds 71, 72 and the member in the vicinity thereof are sectional views). 19A is a perspective view of the mold 71, and FIG. 19B is an exploded perspective view of the mold 71. It is a figure corresponding to FIG. 18 for demonstrating a molding process. It is a front view of the molded body 26. 22A to 22B are front views showing the operation of the movable portion 71g when the first cutting step is performed by the mold 71. It is a perspective view which shows the state which the molded body 26 is sandwiched by the sandwiching device 12 with the molds 71 and 72 closed. FIG. 24A shows a state in which the molds 71 and 72 are removed from FIG. 23, and FIG. 24B is an enlarged view of the region B in FIG. 24A. 25A is a perspective view of the holding device 13, and FIG. 25B is an enlarged view of the region B in FIG. 25A. It is a perspective view of the holding device 13 in a state where the holding mechanism 13e is in a standby state. 27A to 27B are perspective views for explaining a process in which the holding device 13 holds the molded body 26. FIG. 28A is a perspective view showing a state in which the holding device 13 has completed holding of the molded body 26, and FIG. 28B shows a state in which the holding table 13b is tilted to remove the upper burr 26bu. It is a perspective view of the holding device 13 holding a molded body 26 in a state where a holding table 13b is horizontal. It is a perspective view of the head 27 of a manipulator 6. 31A is a perspective view of the holding device 13 holding the molded body 26 for explaining the second cutting step, and FIG. 31B is an enlarged view of the region B in FIG. 31A. It is a perspective view of the state which removed the molded body body 26a from the state of FIG. 31A. 33A is a perspective view of the holding table 13b in a folded state, and FIG. 34B is an enlarged view of the region B in FIG. 34A. The holding mechanism 13e is not shown. FIG. 34A is an end view of the holding table 13b in a folded state. FIG. 34B is an end view of the connecting member 13b2 and the arm 13b3 in a state of being asymmetrically rotated. FIG. 34C is an end view of the arm 13b3 with the lower burr plate 13g and the upper burr plate 13h attached. FIG. 34D is an end view of the holding table 13b in a burr discharge state. The holding mechanism 13e is not shown. It is a perspective view of the holding device 13 and the burr introduction device 17 for demonstrating the discharge process. The holding mechanism 13e is not shown. It is a perspective view of the burr input device 17 for demonstrating the ascending process. FIG. 37A is a perspective view showing a state in which the inspection device 14, the press device 15, and the stacking device 16 are arranged along the conveyor 28. FIG. 37B shows a state in which the molded body main body 26a is removed from FIG. 37A. 37C is a front view of FIG. 37A. FIG. 38A is a perspective view of the inspection device 14 and the conveyor 28 as viewed from the back side. 38B is a right side view of FIG. 38A. FIG. 38C is a right side view of the weighing platform 14a raised from FIG. 38B. FIG. 39A is a perspective view of a state in which the molded body main body 26a is conveyed toward the press device 15 by using the feeding device 29. FIG. 39B is a front view showing a state in which the molded body body 26a is arranged in the press device 15. FIG. 40A is a perspective view showing a state in which the molded body main body 26a is arranged in the stacking device 16. 40B is a right side view of FIG. 40A. 41A to 41C are right side views showing the operation of the stacking device 16 when the molded body main body 26a is stacked.

Hereinafter, embodiments of the present invention will be described. The various features shown in the embodiments shown below can be combined with each other. In addition, the invention is independently established for each characteristic item.

1. 1. Resin panel 1
As shown in FIG. 1, the resin panel 1 (an example of a “structure”) according to an embodiment of the present invention is a panel covered with a substantially rectangular resin molded body 2 in a plan view.

As shown in FIGS. 1 to 2, the resin panel 1 includes a hollow resin molded body 2 and a core material 3, and the core material 3 is arranged in the resin molded body 2. A skin material 4 is attached to one side of the resin molded body 2 so as to extend to the parting line PL. The skin material 4 is, for example, a non-woven fabric, and is integrally molded with the resin molded body 2 at the time of molding.

Both sides of the core material 3 are in close contact with the resin molded body 2. The core material 3 is composed of the bases 3a and 3b and the reinforcing member 3c connecting them. The reinforcing member 3c is an elongated member having a constant cross-sectional shape. The substrates 3a and 3b are made of, for example, a foam. The reinforcing member 3c has a substantially H shape, and is composed of an upper wall 3c1, a lower wall 3c2, and a column portion 3c3 connecting them. Protrusions 3c11 protruding toward the lower wall 3c2 are provided at both ends of the upper wall 3c1 in the width direction. Protrusions 3c21 protruding toward the upper wall 3c1 are provided at both ends of the lower wall 3c2 in the width direction. By engaging the protrusions 3c11 and 3c21 with the bases 3a and 3b, the bases 3a and 3b and the reinforcing member 3c are integrated. At the ends of the bases 3a and 3b, recesses 3a1 and 3b1 that are lowered by one step are provided, and the upper wall 3c1 and the lower wall 3c2 are housed in the recesses 3a1 and 3b1 so that the bases 3a and 3b and the reinforcing member 3c are accommodated. The upper surface and the lower surface of the above are substantially flush with each other.

2. 2. Manufacturing system 20 for resin panel 1
The resin panel 1 can be manufactured by using the manufacturing system 20 shown in FIG. In the manufacturing system 20, only the replenishment of the core material 3 and the skin material 4 and the removal of the molded body main body 26a (see FIG. 41) mounted on the stacking device 16 are performed manually, and other processes are automatic. It is done in. Therefore, the manufacturing system 20 can be operated by a small number of operators (for example, one person) 21. Further, in the manufacturing system 20, the manufacturing lines are arranged in a substantially U shape and can be installed in a relatively small space.

As shown in FIGS. 3 to 5, the manufacturing system 20 includes first and second manipulators 5 and 6, a member supply line 7, a positioning device 8, an insertion device 9, a molding machine 10, and a holding device 12. A holding device 13, a conveyor 28, an inspection device 14, a press device 15, a stacking device 16, a burr input device 17, and a crusher 18. The manipulators 5 and 6 are configured by, for example, attaching a head having a required functional member to a robot arm having 6 or more axes. The first manipulator 5 is configured to be movable on the transport table 5a. The second manipulator 6 is fixed on the mounting table 6a. The holding device 13 is fixed on a transport table 13d configured to be movable along the transport line 13a.

In the following description, the X-axis and Y-axis defined as shown in FIG. 3 will be referred to as appropriate. The X-axis is the transport direction on the transport line 13a. In the transport line 13a, the direction from the pinching device 12 toward the burr input device 17 is defined as the “+ X direction”, and the opposite direction is defined as the “−X direction”. The Y-axis is an axis orthogonal to the X-axis on the horizontal plane. The direction from the positioning device 8 toward the molding machine 10 is defined as the “+ Y direction”, and the opposite direction is defined as the “−Y direction”.

Here, the general flow of the members will be described. First, the core material 3 and the skin material 4 are conveyed from the operator 21 toward the positioning device 8 in the −X direction along the member supply line 7. Next, the core material 3 and the skin material 4 are conveyed from the positioning device 8 toward the molding machine 10 in the + Y direction by the manipulator 5 and the insertion device 9, and are molded by the molding machine 10 to form the molded body 26 shown in FIG. Will be done. The molded body 26 is conveyed in the −Y direction by the holding device 12, and is held by the holding device 13. In the holding device 13, the molded body 26 is separated into a molded body main body 26a and a large burr 26b. The large burr 26b is conveyed in the + X direction by the holding device 13 and is charged into the burr charging device 17. On the other hand, the molded body body 26a is conveyed in the −Y direction toward the conveyor 28 by the manipulator 6, and is conveyed in the + X direction on the conveyor 28. In this way, the molded body body 26a and the large burr 26b are conveyed in the same direction. Further, the core material 3 and the skin material 4 are conveyed in the opposite directions to the molded body main body 26a and the large burr 26b. With such a configuration, it is possible to configure the manufacturing system 20 in a narrow space.

3. 3. Manufacturing Method of Resin Panel 1 The resin panel 1 can be manufactured by carrying out the following manufacturing steps using the manufacturing system 20. The manufacturing method of the resin panel 1 of the present embodiment includes a member replenishment step, a core material delivery step, a skin material delivery step, a molding step, a molded body take-out step, a holding step, a separation step, and a burr treatment. It includes a process and a main body processing process. The holding step, the separating step, and the burr treatment step are performed on the same straight line along the transport line 13a. Hereinafter, each step will be described in detail.

2-1. Member replenishment step In the member replenishment step, the core material 3 and the skin material 4 are replenished using the member supply line 7. As shown in FIGS. 4 to 5, the manufacturing system 20 is provided with two equivalent member supply lines 7, and each member supply line 7 includes a core material transfer table 22 and a skin material transfer table 23. Are provided so as to be separated in the vertical direction. The core material transfer table 22 and the skin material transfer table 23 are configured to be movable along the X axis, for example, by a screw feed mechanism.

A large number of core materials 3 are stacked and placed on the core material transport table 22. When the core material 3 is present on the core material transfer table 22, it is arranged at the standby position shown in FIG. As will be described later, the core material 3 on the core material transfer table 22 is taken out in order from the top by the manipulator 5. When it is detected that the core material 3 has disappeared on the core material transfer table 22, the core material transfer table 22 moves to the replenishment position shown in FIG. When the operator 21 replenishes the core material 3 at the replenishment position, the core material transfer table 22 returns to the standby position.

A large number of skin materials 4 are stacked and placed on the skin material transport table 23. When the skin material 4 is present on the skin material transport table 23, it is arranged at the standby position shown in FIG. As will be described later, the skin material 4 on the skin material transport table 23 is taken out in order from the top by the manipulator 5. When it is detected that the skin material 4 has disappeared on the skin material transport table 23, the skin material transport table 23 moves to the replenishment position shown in FIG. When the operator 21 replenishes the skin material 4 at the replenishment position, the skin material transport table 23 returns to the standby position.

The core material transfer table 22 and the skin material transfer table 23 are provided with locking portions such as pillars, and the core material 3 and the skin material 4 are positioned by pressing the core material 3 and the skin material 4 against the locking portions. You may. Although the core material 3 and the skin material 4 are positioned to some extent by this method, since the core material 3 and the skin material 4 are overlapped with each other, misalignment is likely to occur, and the positioning accuracy of the core material 3 and the skin material 4 is low. A positioning step described later is required.

The skin material transport table 23 moves through the lower side of the core material transfer table 22. As shown in FIGS. 4 and 5B, the standby position of the skin material transport table 23 is below the positioning table 8a of the positioning device 8. Further, in a plan view, the transport table 5a of the manipulator 5 is arranged between the standby position of the skin material transfer table 23 and the standby position of the core material transfer table 22. With such a configuration, it is possible to replenish the core material 3 and the skin material 4 and supply the manipulator 5 in a small space. Further, since the two member supply lines 7 are provided, the supply of the members to the manipulator 5 does not stop even during the replenishment of the members on one of the lines.

2-2. Core material delivery process In the core material delivery process, the core material 3 on the core material transfer table 22 is delivered to the insertion device 9. The core material delivery step includes a core material take-out step, a core material positioning step, a core material holding step, and a core material delivery completion step.

<Core material removal process>
In the core material take-out process (an example of the "take-out process"), a core material stack (an example of the "target member stack") formed by stacking a plurality of core materials 3 (an example of the "target member") is placed on the top of the core material stack (an example of the "target member stack"). The positioned core material 3 is taken out and moved onto the positioning table 8a of the positioning device 8. This step can be performed using the manipulator 5.

The manipulator 5 includes a head 24 shown in FIG. 7 at its tip. The head 24 includes a base 24a, a suction pad 24b, a needle gripper 24c, a male type holding portion 24d, and a reinforcing member positioning mechanism 24e. Each member is held by the base 24a. Details of each member will be described later as appropriate.

The suction pad 24b is used to suck and hold the core material 3. The suction pad 24b is configured so that the amount of protrusion from the base 24a can be adjusted. The number of suction pads 24b required for holding the core material 3 may be provided, and in this embodiment, eight suction pads 24b are provided.

The suction pad 24b has a bellows shape, and is configured to be shortened as the force applied in the direction perpendicular to the suction surface 24b1 of the suction pad 24b increases. The eight suction pads 24b are sucked to different regions of the core material 3, and there may be a difference in height between these regions. In such a case, it was difficult for the conventional suction pad to suck the region at a low position, but in the present embodiment, the suction pad 24b is configured to be shortened according to the force applied to the suction pad 24b. Therefore, when the head 24 is pressed against the core material 3, the suction pad 24b is appropriately shortened according to the height of the region where the suction pad 24b is sucked, so that the core material 3 is surely pressed by all the suction pads 24b. Can be adsorbed.

The manipulator 5 moves the head 24 toward the core material transfer table 22 in a state where the protrusion amount of the suction pad 24b is larger than that of the other members so that the members other than the suction pad 24b do not interfere with the core material 3. , As shown in FIG. 8, the suction pad 24b sucks and holds the core material 3.

By the way, the core material 3 is not accurately positioned on the core material transfer table 22 (that is, there are variations in the positions of the core material 3 on the core material transfer table 22). It is taught in advance that the manipulator 5 adsorbs the core material 3 arranged at the standby position of the core material transfer table 22. Therefore, since the suction pad 24b sucks the core material 3 without recognizing the exact position of the core material 3, the position where the suction pad 24b sucks the core material 3 slightly varies each time it is sucked. Therefore, if the core material 3 is passed to the insertion device 9 as it is, the position of the core material 3 in the insertion device 9 also varies, which leads to variation in the quality of the product. Therefore, in the present embodiment, the core material positioning step shown below is performed.

<Core material positioning process>
In the core material positioning step, the core material 3 is positioned by using the manipulator 5 and the positioning device 8. The core material positioning step includes an inclination step, a substrate position correction step, and a reinforcing member position correction step. The positioning device 8 is provided with a sensor (not shown), and it is possible to detect whether or not the core material 3 or the skin material 4 is present on the positioning table 8a, and when the absence is detected. , The core material removal process can be repeated and a warning can be issued.

-Inclination process The inclination process can be performed by using the positioning device 8. As shown in FIG. 9A, the positioning device 8 includes a positioning table 8a, a locking portion 8b, and a rotation mechanism 8c. As shown in FIG. 4, the rotation mechanism 8c is fixed on the pedestal 8d. The rotation mechanism 8c includes a base 8c1, a first rotation member 8c2, and a second rotation member 8c3. The rotation mechanism 8c includes first and second rotation mechanisms. The first rotating member 8c2 rotates about the first rotating shaft 8c4 parallel to the Y axis with respect to the base 8c1 (first rotating mechanism). The second rotating member 8c3 rotates about the second rotating shaft 8c5 orthogonal to the first rotating shaft 8c4 with respect to the first rotating member 8c2 (first rotating mechanism). The rotation mechanism 8c is configured by, for example, a biaxial robot. The positioning table 8a is connected to the second rotating member 8c3. Therefore, the positioning table 8a is tilted by being driven by the rotation mechanism 8c. The locking portion 8b includes a first locking portion 8b1 and a second locking portion 8b2. The positioning device 8 having such a configuration can also be used for positioning a member (eg, skin material 4) whose characteristics such as thickness and rigidity are significantly different from those of the core material 3.

In the tilting step, as shown in FIG. 9A, the core material 3 is placed on the positioning table 8a, and as shown in FIG. 9B, the rotation mechanism 8c is operated to tilt the positioning table 8a. The core material 3 is positioned by sliding the core material 3 placed on the positioning table 8a and bringing it into contact with the locking portion 8b. At this point, since the core material 3 does not need to be positioned with respect to the positioning table 8a, the core material 3 is placed on the positioning table 8a so as to drop the core material 3 from a few millimeters above the positioning table 8a. You may.

More specifically, in the first rotation shaft rotation step, the core material 3 is slid by rotating the positioning table 8a around the first rotation shaft 8c4 to bring it into contact with the first locking portion 8b1. In the second rotation shaft rotation step, the core material 3 is slid and brought into contact with the second locking portion 8b2 by rotating the positioning table 8a around the second rotation shaft 8c5. The first and second rotation shaft rotation steps may be performed at the same time, or any of them may be performed first.

-Base position correction step By the way, the core material 3 is composed of the bases 3a and 3b and the reinforcing member 3c connecting them, and due to the dimensional variation of the bases 3a and 3b and the like, as shown in FIG. 10B, the base material 3 is formed. The positional relationship between the reinforcing members 3a and 3b and the reinforcing member 3c may be displaced along the longitudinal direction of the reinforcing member 3c. Such a deviation may not be eliminated only by tilting the positioning table 8a.

In the state of FIG. 10, the reinforcing member 3c and the base 3a are respectively displaced in the direction away from the first locking portion 8b1. In this state, the substrate 3b is in contact with the first locking portion 8b1 and is accurately positioned, but the reinforcing member 3c and the substrate 3a are not positioned. Therefore, it is necessary to correct the positions of the reinforcing member 3c and the base 3a.

Therefore, in the substrate position correction step, as shown in FIG. 10, a force is applied to the substrate 3a in the direction of the arrow L to press the substrate 3a against the first locking portion 8b1 along the longitudinal direction of the reinforcing member 3c. The misalignment of the substrate 3a is corrected.

Specifically, this step can be performed by pressing the substrate 3a against the first locking portion 8b1 with the tubular portion 24d2 of the male mold holding portion 24d shown in FIGS. 7A and 7B. As shown in FIG. 17, the cylinder portion 24d2 is originally a member used for pushing the skin material 4 when moving the skin material 4 from the male type protrusion 24d1 to the female type protrusion 9c1. A member other than 24d2 may be used to press the substrate 3a against the first locking portion 8b1.

The substrate 3a may come into contact with the first locking portion 8b1 and be displaced so that the substrate 3b is separated from the first locking portion 8b1. In this case, the substrate 3b is pressed against the first locking portion 8b1. This makes it possible to correct the positional deviation of the substrate 3b along the longitudinal direction of the reinforcing member 3c.

In this step, the positional deviation between the substrates 3a and 3b along the longitudinal direction of the reinforcing member 3c is corrected by the above method.

-Reinforcing member position correction step In the reinforcing member correction step, the positional deviation of the reinforcing member 3c with respect to the bases 3a and 3b is corrected. This step can be performed by using the reinforcing member positioning mechanism 24e shown in FIGS. 7A and 7C.

The head 24 is provided with a pair of reinforcing member positioning mechanisms 24e. The reinforcing member positioning mechanism 24e includes a first base 24e1, a first rod 24e2, a second base 24e3, and a second rod 24e4, respectively. The first base 24e1 is fixed to the base 24a of the head 24. The first rod 24e2 extends along the in-plane direction of the member mounting surface 24a1 of the base 24a of the head 24, and the amount of protrusion from the first base 24e1 can be adjusted. The second base 24e3 is fixed to the first rod 24e2. The second rod 24e4 extends along a direction perpendicular to the member mounting surface 24a1, and the amount of protrusion from the second base 24e3 can be adjusted.

When correcting the deviation of the reinforcing member 3c, as shown in FIG. 11, a pair of first rods 24e4 of the pair of reinforcing member positioning mechanisms 24e are arranged on an extension line in the longitudinal direction of the reinforcing member 3c. The reinforcing member 3c is sandwiched between the pair of second rods 24e4 by moving the two rods 24e4 in the directions of the arrows L1 and L2 to bring the pair of second rods 24e4 closer to each other. As a result, the reinforcing member 3c is arranged at an appropriate position, so that the positional deviation of the reinforcing member 3c with respect to the substrates 3a and 3b is corrected.

<Core material holding process>
In the core material holding step (an example of the “holding step”), the core material 3 is held and moved by the manipulator 5 in a state where the core material 3 is positioned. The holding and moving of the core material 3 by the manipulator 5 can be performed by the same method as the core material extraction step.

<Core material delivery completion process>
In the core material delivery completion step, the manipulator 5 delivers the core material 3 to the insertion device 9. This completes the delivery of the core material.

The insertion device 9 is configured to be movable by a drive mechanism (not shown). As shown in FIG. 12, the insertion device 9 includes a base 9a, a suction pad 9b, and a female holding portion 9c. Each member is held by the base 9a. Details of each member will be described later as appropriate.

The suction pad 9b is used to suck and hold the core material 3. The suction pad 9b is provided at a position facing the suction pad 24b of the head 24.

As shown in FIG. 13, the manipulator 5 starts the suction by the suction pad 9b and stops the suction by the suction pad 24b in a state where the core material 3 is in contact with the suction pad 9b. It can be handed over to the insertion device 9.

2-3. Skin material delivery step In the skin material delivery step, the skin material 4 on the skin material transfer table 23 is delivered to the insertion device 9. The skin material delivery step includes a skin material removal step, a skin material positioning step, a skin material holding step, and a skin material delivery completion step.

<Skin material removal process>
In the skin material taking-out step, the skin material 4 located at the uppermost part of the skin material stack formed by stacking a plurality of skin materials 4 (an example of the “target member”) is taken out, and the skin material 4 is taken out on the positioning table 8a of the positioning device 8. Move to. This step can be performed using the manipulator 5.

As shown in FIG. 4, when the positioning table 8a is horizontal, the positioning table 8a overlaps the skin material transport table 23 in a plan view, and when the skin material 4 is taken out in this state, the skin material 4 is taken out. May interfere with the positioning table 8a. Therefore, before the manipulator 5 holds the skin material 4, the positioning table 8a is rotated so that the positioning table 8a does not overlap the skin material transport table 23 in a plan view. In one example, the positioning table 8a can be rotated so that the positioning table 8a is perpendicular to the skin material transport table 23.

The needle gripper 24c provided on the head 24 of the manipulator 5 is configured to pierce and hold a plurality of needles in a diagonal direction with respect to a breathable member such as a non-woven fabric. In this embodiment, the needle gripper 24c is used to hold the skin material 4. The needle gripper 24c is configured so that the amount of protrusion from the base 24a can be adjusted. The number of needle grippers 24c may be sufficient to hold the skin material 4, and four needle grippers 24c are provided in the present embodiment.

The manipulator 5 moves the head 24 toward the skin material transport table 23 in a state where the protrusion amount of the needle gripper 24c is larger than that of the other members so that the members other than the needle gripper 24c do not interfere with the core material 3. , The needle of the needle gripper 24c is pierced into the skin material 4 and held.

By the way, similarly to the core material 3, the skin material 4 is not accurately positioned on the skin material transport table 23. Therefore, in the present embodiment, the following skin material positioning step is performed.

<Skin material positioning process>
As shown in FIG. 14, in the skin material positioning step, the skin material 4 is positioned by performing the same operation as the tilting step of the core material positioning step.

<Skin material holding process>
In the skin material holding step, the skin material 4 is held and moved by the manipulator 5 in a state where the skin material 4 is positioned. This step can be performed using the manipulator 5.

As shown in FIG. 7B, the male type holding portion 24d provided on the head 24 of the manipulator 5 includes a male type protrusion 24d1, a tubular portion 24d2, and a base 24d3. The male protrusion 24d1 is configured so that the amount of protrusion from the base 24d3 can be adjusted. The male projection 24d1 has a shaft portion 24d11 and a bulging portion 24d12, and the bulging portion 24d12 has a tapered shape toward the tip. As shown in FIG. 15, the male-shaped protrusion 24d1 is inserted through the skin material 4, and the skin material 4 is locked by the swelling portion 24d12, whereby the skin material 4 can be held by the male-shaped holding portion 24d. Become. The tubular portion 24d2 is configured so that the amount of protrusion from the base 24d3 can be adjusted. The male projection 24d1 is arranged in the tubular portion 24d2 and is movable relative to the tubular portion 24d2.

The male type holding portion 24d is arranged at a position slightly outside the outer circumference of the core material 3 so as not to interfere with the core material 3. The number of male type holding portions 24d may be sufficient to hold the skin material 4, and in this embodiment, four are provided.

The skin material 4 is provided with a slit-shaped opening at a position facing the male protrusion 24d1, so that the male protrusion 24d1 can be easily inserted into the skin material 4.

The manipulator 5 moves the head 24 toward the positioning table 8a, pierces the needle of the needle gripper 24c into the skin material 4, and inserts the male protrusion 24d1 into the skin material 4 as shown in FIG. 15B. Hold the material 4. The positioning table 8a is provided with a recess at a position facing the male projection 24d1 in order to avoid interference between the male projection 24d1 and the positioning table 8a.

<Process of completing delivery of skin material>
In the process of completing the delivery of the skin material, the manipulator 5 delivers the skin material 4 to the insertion device 9. As a result, the delivery of the skin material 4 is completed.

As shown in FIG. 12B, the female mold holding portion 9c provided in the insertion device 9 includes a female mold protrusion 9c1, a tubular portion 9c2, and a base 9c3. The female protrusion 9c1 is configured so that the amount of protrusion from the base 9c3 can be adjusted. The female protrusion 9c1 has a shaft portion 9c11 and a bulging portion 9c12, and the tip of the bulging portion 9c12 is provided with a recess 9c13 that can be engaged with the tip of the male protrusion 24d1. The recess 9c13 preferably has a shape complementary to the tip of the male protrusion 24d1.

As shown in FIG. 17E, the female type protrusion 9c1 is inserted through the skin material 4, and the skin material 4 is locked by the swelling portion 9c12, so that the skin material 4 can be held by the female type holding portion 9c. Become. The tubular portion 9c2 is configured so that the amount of protrusion from the base 9c3 can be adjusted. The female projection 9c1 is arranged in the tubular portion 9c2 and is movable relative to the tubular portion 9c2. The female holding portion 9c is provided at a position facing the male holding portion 24d.

Specifically, the skin material 4 is delivered by the following method.

First, as shown in FIGS. 16 and 17A, the male projection 24d1 is opposed to the female projection 9c1 while the skin material 4 is held by the male projection 24d1.

Next, as shown in FIG. 17B, the tip of the male projection 24d1 is engaged with the recess 9c13 of the female projection 9c1. As a result, the male protrusion 24d1 and the female protrusion 9c1 are positioned with high accuracy. In FIG. 17B, the protrusion amount of the female protrusion 9c1 is increased, but the engagement may be executed by increasing the protrusion amount of the male protrusion 24d1.

Next, as shown in FIG. 17C, the skin material 4 is moved to the shaft portion 9c11 by pushing the skin material 4 with the end surface of the tubular portion 24d2. In FIG. 17C, the skin material 4 is pushed by the end surface of the tubular portion 24d2 by increasing the protruding amount of the tubular portion 24d2, but the protruding amount of the male projection 24d1 is reduced and the protrusion amount of the female projection 9c1 is increased. By doing so, the skin material 4 may be pushed by the end face of the tubular portion 24d2.

Next, as shown in FIG. 17D, the tubular portion 24d2 is separated from the skin material 4.

Next, as shown in FIG. 17E, the female projection 9c1 is separated from the male projection 24d1. As a result, the delivery of the skin material 4 is completed.

A sensor 25 for confirming that the skin material 4 has been delivered is provided. As shown by the arrow S, the sensor 25 irradiates the portion where the female protrusion 9c1 is inserted into the skin material 4, and based on the reflected light, whether or not the female protrusion 9c1 is inserted into the skin material 4. Is detected.

2-4. Molding process As shown in FIGS. 18 to 22, in the molding process, the molding machine 10 and the insertion device 9 are used to form the molded body 26 shown in FIG. 21. As shown in FIG. 18, the molding machine 10 includes a pair of sheet forming devices 64, first and second molds 71 and 72, and a lower burr holding device 78.

<Molded body 26>
As shown in FIG. 21, the molded body 26 is configured by connecting the molded body body 26a and the large burr 26b (an example of “burrs”) via a cutting line 26c provided so as to surround the molded body body 26a. ing. Therefore, by cutting the molded body 26 along the cutting line 26c over the entire circumference of the molded body body 26a, the molded body 26 can be separated into the molded body body 26a and the large burr 26b.

The cutting line 26c includes a left line 26cl, a right line 26cr, an upper line 26cu, and a lower line 26cc. In FIG. 21, the left line 26cl and the right line 26cl are indicated by thick lines. The left line 26cl, the right line 26cr, the upper line 26cu, and the lower line 26cc are the left sides of the molded body 26a when the molded body 26 is viewed from the mold closing direction (arrow C2) of the mold 72 shown in FIG. 20, respectively. , Right, upper, and lower.

In the present embodiment, the first cutting step of cutting the molded body 26 along the right line 26cr and the left line 26cl by the dies 71 and 72 is performed, and after the molded body 26 is taken out from the dies 71 and 72, the cutting line 26c is performed. A second cutting step of cutting the molded product 26 along the rest of the above (that is, the upper line 26cu and the lower line 26cc) is performed.

Since the first cutting step can be performed in a shorter time than the second cutting step, the molded body 26 is cut along a part of the cutting line 26c by the dies 71 and 72 in the first cutting step. , The time required for the cutting process can be shortened.

The molded body body 26a is configured by connecting a molded product 26d (corresponding to the resin panel 1) and a small burr 26e via a parting line 26f. Therefore, the molded product 26d and the small burr 26e can be separated by cutting the molded body body 26a along the parting line 26f over the entire circumference of the molded product 26d.

The parting line 26f includes a left line 26fl, a right line 26fr, an upper line 26fu, and a lower line 26fb. The left line 26fl, the right line 26fr, the upper line 26fu, and the lower line 26fb are the left sides of the molded body 26a when the molded body 26 is viewed from the mold closing direction (arrow C2) of the mold 72 shown in FIG. 20, respectively. , Right, upper, and lower.

The left line 26cl and the right line 26cr of the cutting line 26c include the left line 26fl and the right line 26fr of the parting line 26f, respectively. The lower line 26cb of the cutting line 26c overlaps with the lower line 26fb of the parting line 26f.

On the other hand, the upper line 26cu of the cutting line 26c is provided at a position adjacent to the upper side of the upper line 26fu (an example of the "adjacent line") of the parting line 26f. Therefore, the molded product 26d and the small burr 26e are connected via the upper line 26fu.

Since the upper line 26fu of the parting line 26f is non-linear, it takes time to cut the molded body 26 along the upper line 26fu using a cutter. Therefore, in the present embodiment, a linear upper line 26cu is provided at a position adjacent to the upper side of the upper line 26fu, and in the second cutting step, the molded body 26 is cut along the upper line 26cu. This shortens the time required for the second cutting step.

In order to obtain the molded product 26d, it is necessary to perform a third cutting step of cutting the molded body body 26a along the upper line 26fu. However, the third cutting step can be performed after the molded body body 26a is moved from the holding device 13 to another place. Therefore, the time required for the second cutting step performed on the holding device 13 is directly related to the cycle time. In other words, the processing on the holding device 13 is the bottleneck of the manufacturing cycle, and shortening the time required for this processing leads to the shortening of the cycle time. Therefore, the time required for the second cutting step is shortened, and the cycle time can be shortened by performing the third cutting step at a place other than the holding device 13.

The lower line 26cb of the cutting line 26c may be provided below the lower line 26fb of the parting line 26f. The cutting of the molded body 26 along the parting line 26f needs to be performed slowly and carefully so as not to damage the molded body main body 26a, but by providing the lower line 26cc under the lower line 26fb, the second It is possible to speed up cutting along the lower line 26cc in the cutting process.

<Structure of sheet forming apparatus 64>
As shown in FIG. 18, the sheet forming apparatus 64 includes a hopper 62, an extruder 63, an accumulator 67, and a T-die 68. The extruder 63 and the accumulator 67 are connected via a connecting pipe 75. The accumulator 67 and the T-die 68 are connected via a connecting pipe 77. Hereinafter, each configuration will be described in detail.

・ Hopper 62, extruder 63
The hopper 62 is used to charge the raw material resin 61 into the cylinder 63a of the extruder 63. The form of the raw material resin 61 is not particularly limited, but is usually in the form of pellets. The raw material resin is, for example, a thermoplastic resin such as a polyolefin, and examples of the polyolefin include low-density polyethylene, linear low-density polyethylene, high-density polyethylene, polypropylene, an ethylene-propylene copolymer and a mixture thereof. The raw material resin 61 may contain a recycled raw material produced by crushing the large burr 26b with the crusher 18. The raw material resin 61 is charged into the cylinder 63a from the hopper 62 and then heated in the cylinder 63a to be melted into a molten resin. Further, it is conveyed toward the tip of the cylinder 63a by the rotation of the screw arranged in the cylinder 63a. The screw is arranged in the cylinder 63a, and the molten resin is kneaded and conveyed by its rotation. A gear device is provided at the base end of the screw, and the screw is rotationally driven by the gear device.

・ Accumulator 67, T-die 68
The raw material resin is extruded from the resin extrusion port of the cylinder 63a and injected into the accumulator 67 through the connecting pipe 75. The accumulator 67 includes a cylinder 67a and a piston 67b slidable inside the cylinder 67a, and the molten resin 61a can be stored in the cylinder 67a. Then, by moving the piston 67b after a predetermined amount of the molten resin 61a is stored in the cylinder 67a, the molten resin 61a is pushed out from the slit provided in the T-die 68 through the connecting pipe 77 and hung down to be in a molten state. The first and second resin sheets 73a and 73b are formed.

<Structure of molds 71 and 72 and lower burr holding device 78>
The resin sheets 73a and 73b are guided between the molds 71 and 72. The molds 71 and 72 can be divided by the parting surface that comes into contact with the molds 71 and 72, and the molds 71 and 72 form the molded body 26. That is, in the molding step, the molded body 26 is formed by using a pair of divisible molds 71 and 72.

The mold 71 is provided with a large number of vacuum suction holes (not shown), and the resin sheet 73a can be suctioned under reduced pressure to form a shape along the inner surface 71b of the cavity of the mold 71. ing. A pinch-off portion 71d is provided so as to surround the cavity.

The mold 71 has a male protrusion 71e having the same configuration as the male protrusion 24d1. The male projection 71e is provided at a position facing the female projection 9c1. The male protrusion 71e slides with respect to the mold 71 and can be accommodated in the mold 71.

As shown in FIG. 19, the mold 71 has a main body portion 71f and a pair of movable portions 71g that can move relative to the main body portion 71f. The main body 71f is provided with a protrusion 71f1 corresponding to the cutting line 26c and the parting line 26f. The movable portion 71g is provided with a protrusion 71g1 that can be engaged with the resin sheets 73a and 73b. The protrusion 71f1 has a left line protrusion 71f1l and a right line protrusion 7f1r along the left line 26cl and the right line 26cr of the cutting line 26c. The movable portion 71g is separated from the main body portion 71f along the outer edges of the left line protrusion 71f1l and the right line protrusion 7f1r.

The mold 72 is provided with a large number of vacuum suction holes (not shown), and the resin sheet 73b can be suctioned under reduced pressure to form a shape along the inner surface 72b of the cavity of the mold 72. ing. A pinch-off portion 72d is provided so as to surround the cavity.

As shown in FIG. 18, the lower burr holding device 78 is arranged on the lower side of the molds 71 and 72, and includes holding members 78a and 78b. The sandwiching members 78a and 78b are configured to be movable in the same direction as the opening / closing direction of the molds 71 and 72, respectively. When the molded body 26 is taken out from the molds 71 and 72, the lower burr holding device 78 cannot be taken out properly if the molded body 26 is left fitted in one of the molds. (See FIG. 23) is sandwiched and forced to position the molded body 26 at the center position of the molds 71 and 72 when the mold is opened.

<Details of molding process>
Next, the molding process will be described with reference to FIGS. 18 to 21. The molding process includes a skin material mounting process, a hanging process, a shaping process, a core material welding process, and a mold closing process.

-Surface material mounting process In the skin material mounting process, the skin material 4 held by the female mold protrusion 9c1 of the insertion device 9 is moved to the male mold protrusion 71e of the mold 71 to move the skin material 4 to the mold 71. Attach to.

This movement can be performed in the same manner as the movement of the skin material 4 from the male protrusion 24d1 to the female protrusion 9c1 (see FIG. 17). That is, after the female protrusion 9c1 and the male protrusion 71e are opposed to each other, the two are engaged with each other, and in that state, the skin material 4 is pushed by the end face of the tubular portion 9c2 to push the skin material 4 to the shaft of the male protrusion 71e. Can be moved to the department.

-Dripping step In the hanging step, as shown in FIG. 20, the resin sheets 73a and 73b formed by extruding the molten resin 61a from the slit of the T-die 68 and hanging the molten resin 61a are hung between the dies 71 and 72. The resin sheet 73a is hung between the core material 3 and the skin material 4. The resin sheet 73b is hung between the insertion device 9 and the mold 72. In the present embodiment, since the direct vacuum forming using the resin sheets 73a and 73b extruded from the T die 68 as they are is performed, the resin sheets 73a and 73b may be cooled to room temperature and solidified before molding. No, the solidified resin sheets 73a and 73b are not heated before molding.

-Shaping step In the shaping step, the resin sheets 73a and 73b are sucked under reduced pressure by the molds 71 and 72 to shape the resin sheets 73a and 73b. In the mold 71, the resin sheet 73a is shaped along the outer shape of the inner surface 71b of the cavity. The resin sheet 73b is shaped along the inner surface 72b of the cavity. The timing of shaping the resin sheets 73a and 73b may be different. For example, the resin sheet 73b may be shaped after the core material welding step, or the resin sheet 73b may be shaped in the mold clamping step. good.

After the shaping step and before the mold closing step, it is preferable to slide the male mold protrusion 71e and accommodate it in the mold 71. As a result, the male projection 71e is prevented from interfering with the mold 72. The sliding movement of the male projection 71e is preferably performed before the core material welding step. This makes it possible to prevent the holding device 13 from interfering with the male projection 71e.

-Core material welding step In the core material welding step, the core material 3 is welded to the resin sheet 73a. The core material 3 can be welded to the resin sheet 73a by moving the insertion device 9 toward the resin sheet 73a. After welding the core material 3 to the resin sheet 73a, the insertion device 9 is moved to a position outside the movement locus of the molds 71 and 72.

The timing of arranging the core material 3 between the resin sheets 73a and 73b is not limited, and the core material 3 may be arranged between the resin sheets 73a and 73b in the hanging step or the shaping step. Further, the core material 3 may be welded to the resin sheet 73b first.

-Mold closing step In the mold closing step, the molds 71 and 72 are closed by moving the molds 71 and 72 in the directions of the arrows C1 and C2 in FIG. As a result, the resin sheets 73a and 73b are compressed and welded at the portions corresponding to the protrusions 71f1 and 71g1 to form the molded body 26 shown in FIG. 21.

<Details of the first cutting process>
The first cutting step will be described with reference to FIGS. 19, 21 and 22.

In the state after the molding process and before opening the molds 71 and 72, the molded body main body 26a is engaged with the main body portion 71f of the mold 71, and the large burr 26b is a protrusion provided on the movable portion 71g of the mold 71. It is engaged with 71g1. In this state, as shown in FIG. 22A, when the lower side of the movable portion 71g is tilted away from the main body portion 71f, the molded body 26 is torn from the lower side along the left line 26cl and the right line 26cr of the cutting line 26c. It begins to be disconnected. Next, as shown in FIG. 22B, when the movable portion 71g is moved so that the upper side of the movable portion 71g is separated from the main body portion 71f, the tearing of the molded body 26 proceeds upward and the first cutting step is performed. Complete.

2-5. Mold take-out step In the molded body take-out step, as shown in FIG. 23, the molded body 26 is made of gold by using the holding device 12 in a state where the lower burrs 26bb are held by the holding members 78a and 78b of the lower burr holding device 78. It is taken out from the molds 71 and 72 and transferred to the holding device 13.

The sandwiching device 12 is configured to be driveable by a drive mechanism (not shown). As shown in FIG. 23, the sandwiching device 12 sandwiches the molded body 26 above the molds 71 and 72 with the molds 71 and 72 closed. In other words, the sandwiching device 12 sandwiches the upper burr 26bu of the molded body 26. In this state, as shown in FIG. 24, the molds 71 and 72 are opened. At this time, there is a possibility that the molded body 26 may fit into any of the molds 71 and 72, but in the present embodiment, since the lower burr holding device 78 holds the lower burr 26bb, the molded body 26 is made of gold. It smoothly separates from the molds 71 and 72 without fitting into the molds 71 and 72. After that, the holding device 12 moves the molded body 26 toward the holding device 13. As shown in FIGS. 21 and 24B, the molded body 26 is cut along the left line 26cl and the right line 26cr of the cutting line 26c. On the other hand, the molded body 26 is not cut along the upper line 26cu and the lower line 26cc of the cutting line 26c. If the molded body 26 is cut along any of the upper line 26cu and the lower line 26cc, the molded body body 26a tends to shake with respect to the large burr 26b, which makes it difficult to handle. However, in the present embodiment, this is difficult. At this point, the molded body 26 is cut along only the left line 26cl and the right line 26cr, so that the molded body 26 is easy to handle.

2-6. Holding step In the holding step, the molded body 26 is held by the holding device 13.

<Structure of holding device 13>
As shown in FIG. 25, the holding device 13 includes a holding table 13b, a rotating mechanism 13c, and a holding mechanism 13e. As shown in FIG. 3, the rotation mechanism 13c is fixed on the transfer table 13d, and the transfer table 13d is configured to be movable along the transfer line 13a.

The rotation mechanism 13c includes a base 13c1, a first rotation member 13c2, and a second rotation member 13c3. The rotation mechanism 13c includes first and second rotation mechanisms. The first rotating member 13c2 rotates about the first rotating shaft 13c4 parallel to the Y axis with respect to the base 13c1 (first rotating mechanism). The second rotating member 13c3 rotates about the second rotating shaft 13c5 orthogonal to the first rotating shaft 13c4 with respect to the first rotating member 13c2 (second rotating mechanism). The rotation mechanism 13c is configured by, for example, a biaxial robot. The holding table 13b is connected to the second rotating member 13c3. Therefore, the rotation mechanism 13c can be operated to rotate the holding table 13b.

The holding base 13b includes a base 13b1, a pair of connecting members 13b2, and a pair of arms 13b3. The base 13b1 and the arm 13b3 are connected via the connecting member 13b2. The base 13b1 is arranged between the pair of connecting members 13b2. The arm 13b3 is connected to each connecting member 13b2. The connecting member 13b2 is configured to be rotatable with respect to the base 13b1 around the rotating shaft 13b4. The arm 13b3 is configured to be rotatable with respect to the connecting member 13b2 around the rotation shaft 13b5. Therefore, the arm 13b3 is configured to be rotatable with respect to the base 13b1.

The holding table 13b includes a holding surface 13f, and holds the molded body 26 on the holding surface 13f. As shown in FIG. 34, the holding surfaces of the base 13b1, the connecting member 13b2, and the arm 13b3 are referred to as holding surfaces 13f1, 13f2, 13f3, respectively.

The state of the holding table 13b changes between a flat state, a folded state, and a burr discharge state. In the flat state, the holding surfaces 13f1, 13f2, 13f3 are flush with each other. As shown in FIGS. 33B and 34A, the folded state is a state in which the connecting member 13b2 is rotated with respect to the base 13b1 and the arm 13b3 is rotated with respect to the connecting member 13b2, and the large burr 26b is folded. The holding table 13b is put into a folded state when performing the above. As shown in FIG. 34D, the burr discharge state is a state in which the holding surfaces 13f1 and 13f2 are flush with each other and the arm 13b3 is rotated with respect to the connecting member 13b2. When discharging toward 17, the holding table 13b is set to the burr discharge state.

The holding mechanism 13e includes a base 13e1, a rod 13e2, and a holding portion 13e3. The molded body 26 can be held by sandwiching the molded body 26 between the pressing portion 13e3 and the holding table 13b. The base 13e1 is fixed to the holding table 13b. The rod 13e2 is arranged so as to extend perpendicularly to the holding surface 13f, and the amount of protrusion from the base 13e1 and the holding surface 13f (that is, expansion and contraction of the rod 13e2) is adjustable. The holding portion 13e3 is fixed to the rod 13e2. Therefore, the distance between the holding portion 13e3 and the holding surface 13f can be adjusted. Further, the rod 13e2 is rotatable with respect to the base 13e1 about its own central axis. Therefore, the holding portion 13e3 is configured to be rotatable around the rod 13e2.

The holding mechanism 13e can switch between a standby state, a ready state, an overlapping state, and a holding state by expanding and contracting the rod 13e2 and rotating the holding portion 13e3. In the standby state and the ready state, when the holding surface 13f is viewed from the direction perpendicular to the holding surface 13f (hereinafter referred to as "holding surface view"), the holding portion 13e3 does not overlap the holding surface 13f. Arranged like this. In the standby state, the rod 13e2 is in a contracted and contracted state. In the prepared state, the rod 13e2 is in an extended state in which it is extended more than in the contracted state. In the overlapping state and the holding state, the holding portion 13e3 is arranged so as to overlap the holding surface 13f in the holding surface view. The overlapping state is a state in which the rod 13e2 is in an extended state and the pressing portion 13e3 is not pressing the molded body 26. It is in a pressed state.

As shown in FIG. 26, in the standby state, the heights of the upper surfaces 13e21 and 13e31 of the rod 13e2 and the holding portion 13e3 are lower than the holding surface 13f. More specifically, the heights of the rods 13e2 of the holding mechanism 13e provided on the base 13b1 and the upper surfaces 13e21 and 13e31 of the holding portion 13e3 are lower than the holding surface 13f1 and the holding provided on the arm 13b3. The heights of the upper surfaces 13e21 and 13e31 of the rod 13e2 and the holding portion 13e3 of the mechanism 13e are lower than those of the holding surface 13f3. According to such a configuration, the interference between the holding mechanism 13e and the large burr 26b is suppressed when the large burr 26b is folded.

When pressing the molded body 26, the state of the holding mechanism 13e is changed in the order of the prepared state, the overlapping state, and the pressed state. When the pressing of the molded body 26 is released, the state of the holding mechanism 13e is changed in the order of the pressing state, the overlapping state, and the prepared state. If necessary, the state may be changed from the ready state to the standby state and vice versa. By pressing and releasing the molded body 26 by such a method, the molded body 26 can be appropriately held.

The holding mechanism 13e is classified into an upper holding mechanism 13eu, a central holding mechanism 13ec, and a lower holding mechanism 13eb. The upper holding mechanism 13eu and the lower holding mechanism 13eb are arranged on the upper side and the lower side of the central holding mechanism 13ec in a state where the holding surface 13f is erected as shown in FIG. 25, respectively. The central holding mechanism 13ec is provided on the base 13b1. The upper holding mechanism 13eu and the lower holding mechanism 13eb are provided on the arm 13b3.

As shown in FIG. 21, when the large burr 26b is divided into an upper burr 26bu, a central burr 26bc, and a lower burr 26bb, as shown in FIG. 28A, the upper holding mechanism 13eu, the central holding mechanism 13ec, and the lower holding mechanism 13eb Holds the upper burr 26bu, the central burr 26bc, and the lower burr 26bb, respectively. The central holding mechanism 13ec holds the molded body 26a before separating the molded body 26a.

Since the central burr 26bc is formed by being sandwiched between the molds 71 and 72 in whole or in large part, the thickness is unlikely to increase. The lower burr 26bb includes a portion where the resin sheets 73a and 73b extend below the molds 71 and 72, and this portion is amorphous and the resin sheets 73a and 73b are formed when the resin sheets 73a and 73b are formed. Is pulled toward the molds 71 and 72, so that the thickness (in other words, the distance between the resin sheets 73a and 73b) tends to increase. Therefore, in order to prevent the arm 13b3 of the lower holding mechanism 13eb from interfering with the lower burr 26bb, as shown in FIG. 25A, the holding portion 13e3 of the lower holding mechanism 13eb is made shorter than the holding portion 13e3 of the central holding mechanism 13ec. ing.

Further, since the upper burr 26bu also includes a portion not sandwiched between the molds 71 and 72, the thickness tends to increase. However, since the upper burr 26bu is sandwiched between the holding devices 12, it is unlikely to have an irregular shape like the lower burr 26bb. Therefore, the holding portion 13e3 of the upper holding mechanism 13eu may have the same length as the holding portion 13e3 of the central holding mechanism 13ec, or may be shorter than this.

<Holding method of molded body 26>
First, as shown in FIG. 27A, the holding table 13b is made flat, the holding surface 13f is erected so that the holding surface 13f is substantially parallel to the molded body 26, and all the holding mechanisms 13e are in the ready state. In this state, the molded body 26 is brought close to the holding surface 13f.

In a state where the molded body 26 is located closer to the holding surface 13f than the holding portion 13e3 of the central holding mechanism 13ec, the central holding mechanism 13ec is overlapped by rotating the holding portion 13e3, and further, the central holding mechanism 13ec By shrinking the rod 13e2 into a pressed state, the molded body 26 is pressed by the pressing portion 13e3 to bring it into the state shown in FIG. 27B. At this point, the upper holding mechanism 13eu and the lower holding mechanism 13eb are still in the ready state.

Next, the upper holding mechanism 13eu and the lower holding mechanism 13eb are changed in the order of the overlapping state and the holding state to bring them into the state shown in FIG. 28A. At this point, the molded body 26 is held by all the holding mechanisms 13e.

By the way, the length of the rod 13e2 of the central holding mechanism 13ec in the overlapping state is longer than the length of the rod 13e2 of the upper holding mechanism 13eu and the lower holding mechanism 13eb. With this configuration, the molded body 26 can be pressed against the holding surface 13f even when the molded body 26 is separated from the holding surface 13f to some extent. On the other hand, since the upper holding mechanism 13eu and the lower holding mechanism 13eb start operating in a state where the central holding mechanism 13ec presses the molded body 26 against the holding surface 13f, it is not necessary to lengthen the rod 13e2. Therefore, for the upper holding mechanism 13eu and the lower holding mechanism 13eb, the time required for operation is shortened by shortening the rods 13e2 in the overlapped state.

Next, after the holding device 12 is separated from the molded body 26, the holding table 13b is rotated by rotating the first rotating member 13c2 with respect to the base 13c1, and the holding surface 13f is rotated as shown in FIG. 29. Is the first horizontal state in which is horizontal. In this way, the holding table 13b is rotated by the rotating mechanism 13c (more specifically, the first rotating mechanism) at the time of transition from the holding step to the separation step described later. Further, at this time, the transfer table 13d fixing the rotation mechanism 13c is moved along the transfer line 13a in the direction approaching the burr input device 17 (+ X direction) to adjust the position.

By the way, if the holding device 12 is detached in the state of FIG. 28A, the upper burr 26bu may be bent by gravity and overlap with the molded body body 26a. In such a state, there is a problem that it is difficult to perform the separation step described later.

Therefore, in the present embodiment, while the state of FIG. 28A is changed to the state of FIG. 29, as shown in FIG. 28B, the holding table 13b is tilted so that the upper burr 26bu is lowered to form the upper burr 26bu. A dispelling process is performed to dispel from the main body 26a.

Next, as shown in FIG. 31A, by rotating the second rotating member 13c3 by 90 degrees with respect to the first rotating member 13c2, the holding table 13b is rotated in the horizontal plane to bring it into the second horizontal state. The purpose of making the second horizontal state is to move the head 27 by matching the moving direction of the head 27 provided in the manipulator 6 with the transport direction of the transport line 13a when the second cutting step by the manipulator 6 is performed. It is necessary to reduce the space to be secured and to smoothly carry out the burr discharge process described later.

2-6. Separation step In the separation step, the molded body main body 26a is separated from the molded body 26, and a large burr 26b is left on the holding table 13b. The separation step includes a second cutting step and a transfer step. This step can be performed using the manipulator 6.

<Structure of manipulator 6>
The manipulator 6 includes a head 27 shown in FIG. 30 at its tip. As shown in FIG. 30, the head 27 includes a base 27a, a suction pad 27b, an image pickup unit 27c, and a cutter 27d. Each member is held by the base 27a.

The suction pad 27b is used to suck and hold the molded body body 26a after separation. The suction pad 27b is configured so that the amount of protrusion from the base 27a can be adjusted. The number of suction pads 27b may be sufficient to hold the molded body body 26a, and in this embodiment, six suction pads 27b are provided. The suction pad 27b has a bellows shape similar to the suction pad 24b of the head 24, and even if there is a height difference in the region where the suction pad 27b is sucked, all the suction pads 24b reliably suck the molded body body 26a. be able to.

The imaging unit 27c has a function of imaging the molded body 26a and recognizing the position of the identification shape 26g (see FIG. 31B) provided on the molded body 26a. The cutter 27d is used to cut the compact 26 along the upper line 26cu and the lower line 26cc. The cutter 27d is configured so that the amount of protrusion from the base 27a can be adjusted. The identification shape 26g is, for example, a characteristic uneven structure provided on the molded body main body 26a.

<Second cutting process>
The second cutting step is performed by cutting the molded body 26 along the upper line 26cu and the lower line 26cc shown in FIG. 21 and separating the molded body 26 into the molded body main body 26a and the large burr 26b.

Since the molded body 26 is not accurately positioned on the holding table 13b, the exact positions of the upper line 26cu and the lower line 26cc are not determined. Therefore, the imaging unit 27c recognizes the position of the identification shape 26g, determines the positions of the upper line 26cu and the lower line 26cc based on the recognized positions, and as shown in FIG. 31B, the determined upper line 26cu and lower line 26cc. The second cutting step is performed by moving the cutter 27d along the above. If either the upper line 26cu or the lower line 26cc is cut in the first cutting step, the large burr 26b tends to overlap the molded body body 26a, and in this case, it becomes difficult to recognize the position of the identification shape 26g. However, in the present embodiment, neither the upper line 26cu nor the lower line 26cc is cut in the first cutting step, so that such a problem does not occur.

Further, even if the holding table 13b is rotated 180 degrees in the horizontal plane after cutting along one of the upper line 26cu and the lower line 26cc, the cutting is performed along the other of the upper line 26cu and the lower line 26cc. good. In this case, the amount of movement of the head 27 is reduced, so that it is possible to work in a narrow space.

<Transport process>
The transfer step is performed by sucking and holding the molded body body 26a with the suction pad 27b and transporting it to the conveyor 28. When the central holding mechanism 13 ec is in the pressed state, the molded body main body 26a cannot be conveyed. Therefore, as shown in FIG. 32, the central holding mechanism 13 ec is put into a ready state or a standby state in advance, and then the transfer step is performed. conduct. After the molded body body 26a is conveyed, the central holding mechanism 13ec is put into a pressing state, and the central burr 26bc is pressed by the pressing portion 13e3. The central holding mechanism 13ec presses the molded body body 26a with the pressing portion 13e3 until before the conveying process, and presses the central burr 26bc with the pressing portion 13e3 after the conveying process. The thickness of the molded body body 26a and the central burr 26bc are different, and the lower limit of the clamp cylinder constituting the central holding mechanism 13ec is used to appropriately press the two types of members having different thicknesses. The limit switch is not activated.

2-7. Burr treatment step In the burr treatment step, the large burrs 26b left on the holding table 13b in the separation step are treated. The burr treatment step includes a folding step, a discharging step, an ascending step, and a feeding step.

<Folding process>
In the folding step, the large burr 26b placed on the holding table 13b is folded so that the large burr 26b can be easily handled. The folding process includes a preliminary folding process, a returning process, and a main folding process. At the start of the folding process, the large burr 26b is placed so as to straddle the base 13b1, the pair of connecting members 13b2, and the pair of arms 13b3.

In the preliminary folding step, the holding table 13b is brought into a folded state by rotating the connecting member 13b2 and the arm 13b3 while the large burr 26b is held by the holding mechanism 13e (not shown in FIGS. 33 to 35). As a result, as shown in FIG. 33B, the large burr 26b is folded to form a crease 26h in the large burr 26b. As shown in FIG. 34A, the angle α between the holding surface 13f1 of the base 13b1 and the holding surface 13f3 of the arm 13b3 in the folded state is, for example, 3 to 45 degrees, preferably 8 to 20 degrees. Specifically, the angle α is, for example, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 15, 20, 25, 30, 35, 40, 45 degrees. It may be within the range between any two of the numerical values exemplified here. The angle β between the holding surface 13f1 of the base 13b1 and the holding surface 13f2 of the connecting member 13b2 is preferably 70 to 110 degrees, more preferably 80 to 100 degrees. Specifically, this angle β is, for example, 70, 75, 80, 85, 90, 95, 100, 105, 110 degrees, even if it is within the range between any two of the numerical values exemplified here. good. In this embodiment, the angle α is 13 degrees and the angle β is 90 degrees.

Although it is possible to fold the large burr 26b by rotating only the arm 13b3, it is easy to reduce the angle α by rotating both the connecting member 13b2 and the arm 13b3.

In the preliminary folding step, the connecting member 13b2 and the arm 13b3 are rotated in a state where the crease 26h is not formed in the large burr 26b. Therefore, if the connecting member 13b2 and the arm 13b3 are rotated without fixing the large burr 26b to the holding base 13b, the large burr 26b is lifted by the arm 13b3 without being folded, and the large burr 26b is properly folded. There is no risk. Therefore, in the preliminary folding step, the connecting member 13b2 and the arm 13b3 are rotated while the large burr 26b is held by the holding mechanism 13e.

Further, the large burr 26b may be held by at least one holding mechanism 13e, but the upper burr 26bu, the central burr 26bc, and the lower burr 26bb may be held by the upper holding mechanism 13eu, the central holding mechanism 13ec, and the lower holding mechanism 13eb. It is preferable to hold. In this case, the possibility that the large burr 26b is lifted by the arm 13b3 is further reduced.

In the return step, the connecting member 13b2 and the arm 13b3 are rotated in the direction opposite to the preliminary folding step to increase the angle α. Preferably, in the return step, the connecting member 13b2 and the arm 13b3 are rotated until the angle α becomes 180 degrees. This step is performed in a state where the large burr 26b is held by the holding mechanism 13e, and the folded large burr 26b is unfolded as the arm 13b3 rotates.

In this folding step, the holding table 13b is brought into a folded state by rotating the connecting member 13b2 and the arm 13b3, respectively, in a state where the holding mechanism 13e is released from holding the large burr 26b. Since the return step is performed, it is easy to release the holding of the large burr 26b by the holding mechanism 13e. Further, after the large burr 26b is unfolded in the return step, the large burr 26b is folded at the position of the crease 26h formed in the preliminary folding step, so that the crease 26h of the large burr 26b becomes more prominent and the large burr 26b is folded. It becomes difficult to restore to the state where it has not been done. In the main folding step, it is preferable that the holding mechanism 13e is in a standby state. In this case, interference between the holding mechanism 13e and the large burr 26b can be avoided.

The angles α and β in the main folding step may be the same as those in the preliminary folding step, or may be smaller than those in the preliminary folding step. In the main folding step, since the folding is performed in a state where the holding of the large burr 26b by the holding mechanism 13e is released, it is easy to reduce the angle α.

When folding the large burr 26b, the connecting member 13b2 and the arm 13b3 on the upper burr 26bu side and the connecting member 13b2 and the arm 13b3 on the lower burr 26bb side may be rotated at the same time or may be rotated in order. .. For example, after rotating the connecting member 13b2 and the arm 13b3 on the upper burr 26bu side as shown in FIG. 34A and then performing the return step, the connecting member 13b2 and the arm 13b3 on the lower burr 26bb side are shown in FIG. 34A. The return step may be performed after the rotation.

The connecting member 13b2 and the arm 13b3 on the upper burr 26bu side and the connecting member 13b2 and the arm 13b3 on the lower burr 26bb side may be rotated symmetrically or asymmetrically. For example, in the example of FIG. 34B, the arm 13b3 is rotated with respect to the connecting member 13b2 without rotating the connecting member 13b2 with respect to the base 13b1 on the left side, and the arm 13b3 is rotated with respect to the base 13b1 on the right side. The connecting member 13b2 is rotated, and the arm 13b3 is not rotated with respect to the connecting member 13b2. In this case, the positions of the creases 26h formed in the large burr 26b are different on the left and right, and the distance from the left crease 26h to the left end of the large burr 26b is shorter than the distance from the right crease 26h to the right end of the large burr 26b. Therefore, by folding the large burr 26b first at the crease 26h on the left side and then folding the large burr 26b at the crease 26h on the right side, the folded large burr 26b can be easily organized neatly.

In order to facilitate the formation of the crease 26h in the large burr 26b, the molds 71 and 72 may be provided with protrusions to compress the resin sheet at the position where the crease 26h is formed to reduce the wall thickness.

As shown in FIG. 34C, the lower burr plate 13g suitable for the lower burr 26bb may be attached to the arm 13b3 on the lower burr 26bb side, and the arm 13b3 on the upper burr 26bu side may be fitted with the upper burr 26bu. The upper burr plate 13h may be attached. In this case, even if the large burr 26b protrudes from the holding table 13b, the large burr 26b can be stably held and folded.

<Discharge process>
In the discharge step, the large burr 26b is discharged from the holding device 13 toward the burr charging device 17.

As shown in FIG. 35, the burr input device 17 includes a burr receiver 17a for receiving the large burr 26b and an enclosure 17b surrounding the burr receiver 17a. The burr receiver 17a includes a bottom wall 17a1 and a pair of side walls 17a2 rising from the bottom wall 17a1. The enclosure 17b includes a back wall 17b1 and a pair of side walls 17b2 perpendicular to the back wall 17b1. The side wall 17a2 is provided along the side wall 17b2. The back wall 17b1 is arranged on the back side of the burr receiver 17a when viewed from the holding table 13b. The back wall 17b1 prevents the large burr 26b on the burr receiver 17a from falling to the back side of the burr receiver 17a.

In the discharge step, by tilting the holding table 13b, the large burr 26b placed on the holding table 13b is slid and discharged toward the burr receiving 17a. In this way, at the time of transition from the separation step to the discharge step, the holding table 13b is rotated by the rotation mechanism 13c (more specifically, the first rotation mechanism).

When the holding table 13b is in the folded state, the friction between the large burr 26b and the holding table 13b is large, so that the large burr 26b does not slip easily even if the holding table 13b is tilted. Therefore, prior to the discharge step, at least one of the connecting member 13b2 and the arm 13b3 is rotated so that the angles α and β become large so that the holding table 13b is in the burr discharge state shown in FIGS. 34D and 35. Is preferable. This makes it easier to slide the large burr 26b from the holding table 13b. In the present embodiment, the angle α is 103 degrees and the angle β is 180 degrees in the burr discharge state.

By the way, if there is a recess on the holding table 13b for escape when the molded body 26 is cut by the cutter 27d, the large burr 26b may be caught in the recess, but in the present embodiment, such a recess is held. Since it is not provided on the table 13b, the large burr 26b will not be caught.

Since there is a gap between the holding table 13b and the burr receiver 17a, there is a risk that the large burr 26b will fall from the gap when the large burr 26b is moved to the burr receiver 17a. In order to prevent such a fall, as shown in FIG. 35, the burr receiver 17a is tilted so that the holding table 13b side becomes higher at the time of discharging. In this case, since the large burr 26b that has moved to the burr receiver 17a quickly slides to the back side of the burr receiver 17a, it is possible to prevent the large burr 26b from falling from the front side of the burr receiver 17a. Further, since the back wall 17b1 is located on the back side of the burr receiver 17a, it is possible to prevent the large burr 26b from falling from the back side of the burr receiver 17a. Whether or not the large burr 26b has moved to the burr receiver 17a can be detected by a sensor provided on the holding table 13b or the burr receiver 17a.

<Climbing process>
As shown in FIG. 36, the back wall 17b1 is provided with a charging port 17b11 for the crusher 18 at a position higher than the position of the burr receiving 17a in the discharging process. In the ascending step, the burr receiver 17a is raised toward the input port 17b11. The burr receiver 17a is raised in a substantially vertical direction by the lifter. When the input port of the crusher 18 is in a high position, a large space is required to convey the burr to the input port using the conveyor, but in the present embodiment, the burr receiver 17a is raised in a substantially vertical direction. This makes it possible to put the large burr 26b into the crusher 18 in a narrow space.

This ascending step can be performed while the burr receiver 17a is tilted, but in that case, the large burr 26b is always rubbed against the back wall 17b1, and the back wall 17b1 is worn. In order to suppress such wear, as shown in FIG. 36, it is preferable that the ascending step is performed with the burr receiver 17a horizontal.

In addition, the large burr 26b can be cooled during this ascending step. As a result, the temperature of the large burr 26b charged into the crusher 18 is lowered, and the deterioration of the crusher 18 is suppressed. Cooling can be performed by blowing wind on the large burr 26b. In order to improve the air permeability, the burr input device 17 may have a mesh structure at a portion where the large burr 26b is not likely to be caught.

Further, by slowly performing this ascending step, it is possible to prolong the time until the large burr 26b is charged into the crusher 18 after the separation step. As a result, when it is detected that the skin material 4 is not present in the molded body 26a or the cutter 27d is broken in the inspection step included in the main body processing step described later, the large burr 26b is crushed by the crusher. It becomes possible to stop the burr charging device 17 before it is charged into 18. From this point of view, it is preferable that the ascending step takes a longer time than the inspection step. Further, since it is necessary to return the burr receiver 17a to a low position before the large burr 26b generated in the next cycle is discharged toward the burr receiver 17a, the time of the ascending step is preferably 0.9 cycle time or less. , 0.8 cycle time or less is more preferable.

<Injection process>
In the charging step, after the burr receiver 17a is raised to the charging port 17b11, the burr receiving 17a is tilted and the large burr 26b is charged into the crusher 18 through the charging port 17b11. In the crusher 18, the large burr 26b is crushed to generate a recycled raw material.

2-8. Main body processing step In the main body processing step, an inspection step, a pressing step, a stacking step, and a post-step are performed on the molded body main body 26a. As shown in FIG. 37, the inspection step, the pressing step, and the stacking step are carried out by the inspection device 14, the pressing device 15, and the stacking device 16, respectively. The molded body body 26a is conveyed by using the conveyor 28 and the feeding device 29. In FIGS. 37A and 37C, the molded body 26a is placed on the conveyor 28 above the inspection device 14, and the molded body 26a manufactured in the previous cycle is mounted on the stacking device 16. It is placed.

The conveyor 28 is, for example, a roller conveyor. The feeding device 29 includes a base 29a, a rod 29b, and a tip portion 29c. The rod 29b is configured so that the amount of protrusion from the base 29a can be adjusted. The tip portion 29c is fixed to the tip of the rod 29b. The molded body 26a can be moved by pushing the side surface of the molded body 26a with the tip portion 29c by extending the rod 29b while the molded body 26a is placed on the conveyor 28. Instead of using the feeding device 29, the conveyor 28 itself may be driven to move the molded body body 26a. Further, the conveyor 28 does not pass through the press device 15, and in the press device 15, the molded body body 26a slides on the lower wall 15a shown in FIG. 39.

<Inspection process>
In the inspection step, the inspection device 14 is used to inspect the molded body body 26a conveyed on the conveyor 28. Here, a weight inspection and a skin material deviation inspection are performed.

As shown in FIGS. 38A to 38B, the inspection device 14 includes a weighing table 14a, a weighing device 14b, a sensor 14c, and an elevating device 14d. The elevating device 14d includes a base 14d1 and a rod 14d2. The rod 14d2 is configured so that the amount of protrusion from the base 14d1 can be adjusted. The weighing device 14b is fixed to the rod 14d2. The weighing table 14a is fixed to the weighing device 14b. The weighing device 14b can measure the weight of an object placed on the weighing table 14a. The sensor 14c is fixed to the weighing platform 14a. The sensor 14c is configured to be capable of measuring the reflectance in the vicinity of the upper right and upper left of the molded body body 26a.

In the inspection device 14, as shown in FIG. 38B, the upper surface of the weighing table 14a is lower than the upper surface of the conveyor 28 (the surface where the molded body body 26a abuts on the conveyor 28) during standby. In this state, the weighing device 14b cannot measure the weight of the molded body body 26a.

At the time of inspection, the inspection device 14 raises the weighing table 14a to support the molded body body 26a on the upper surface of the weighing table 14a, as shown in FIG. 38C. In this state, the weighing device 14b can measure the weight of the molded body body 26a.

Further, the molded body body 26a is placed so that the skin material 4 is on the lower side, and the sensor 14c has the skin material 4 near the upper right and upper left of the molded body body 26a through the measurement of the reflectance. It is possible to detect whether or not it is. If the absence of the skin material 4 is detected in only one of the upper right and the upper left, the molded body 26a is regarded as a defective product and removed from the conveyor 28. On the other hand, if the skin material 4 is not present in both the upper right and the upper left, the skin material 4 may fall and adhere to the large burr 26b. If the skin material 4 is charged into the crusher 18, the quality of the recycled raw material deteriorates. Therefore, the burr charging device 17 is stopped until it is confirmed that the skin material 4 does not adhere to the large burrs 26b.

In the inspection process, it may be inspected whether the cutter 27d is broken. This inspection can be performed by confirming whether the length of the cutter 27d is equal to or larger than the reference value. If the length of the cutter 27d is less than the reference value, there is a possibility that the cutter 27d is broken or the cutter 27d is worn and shortened. Therefore, in such a case, the burr charging device 17 can be stopped so that the broken portion of the cutter 27d is not charged into the crusher 18.

After the inspection step, as shown in FIG. 39A, the molding body 26a is placed on the conveyor 28 by lowering the weighing table 14a, and in that state, the side surface of the molded body body 26a is pushed by the tip portion 29c to form the molded body. The body body 26a is moved toward the press device 15.

<Press process>
In the pressing step, the press device 15 is used to press the molded body 26a to improve the flatness of the molded body 26a. As shown in FIG. 39, the press device 15 includes a lower wall 15a, an upper wall 15b, and a pressurizing device 15c. The pressurizing device 15c includes a base 15c1 and a rod 15c2. The rod 15c2 is configured so that the amount of protrusion from the base 15c1 can be adjusted. The pressing process can be carried out by extending the rod 15c2 and pressing the upper wall 15b against the molded body 26a in a state where the molded body 26a is arranged between the lower wall 15a and the upper wall 15b.

After the pressing step, the upper wall 15b is raised, and then the side surface of the molded body 26a is pushed by the tip portion 29c to move the molded body 26a toward the stacking device 16.

<Stacking process>
In the stacking step, the stacking device 16 is used to stack the plurality of molded body bodies 26a. As shown in FIG. 40, the stacking device 16 includes a pair of cylinder units 16a. Each cylinder unit 16a includes a first base 16a1, a first rod 16a2, a second base 16a3, a second rod 16a4, and a stack guide 16a5. The first base 16a1 is fixed to a member (not shown). The first rod 16a2 extends in the width direction of the conveyor 28, and the amount of protrusion from the first base 16a1 can be adjusted. The second base 16a3 is fixed to the first rod 16a2. The second rod 16a4 extends in the height direction, and the amount of protrusion from the second base 16a3 can be adjusted. The stack guide 16a5 is fixed to the second rod 16a4. With such a configuration, the stack guide 16a5 can be moved in the vertical direction and the width direction of the conveyor 28.

In the state of FIG. 39B, the stack guide 16a5 is in the raised position, and the molded body body 26a manufactured in the previous cycle is placed on the stack guide 16a5. In this state, there is a gap equal to or larger than the thickness of the molded body body 26a between the lower surface of the stack guide 16a5 and the conveyor 28. The molded body 26a after the pressing step is pushed by the tip portion 29c and is accommodated in the gap between the lower surface of the stack guide 16a5 and the conveyor 28, as shown in FIG. 40. The two molded body bodies 26a of FIG. 40 are separated by the stack guide 16a5, and are not stacked at this point.

FIG. 41A shows a state in which the width between the pair of stack guides 16a5 is widened beyond the width of the molded body body 26a from the state of FIG. 40. In this state, the molded body main body 26a placed on the stack guide 16a5 is dropped onto the lower molded body main body 26a and stacked.

FIG. 41B shows a state in which the pair of stack guides 16a5 are lowered from the state of FIG. 41A and the space between them is narrowed. When the stack guide 16a5 is raised from this state, the two molded body bodies 26a are lifted by the stack guide 16a5. A gap equal to or larger than the thickness of the molded body body 26a is provided between the lower surface of the stack guide 16a5 and the conveyor 28, and the molded body body 26a formed in the next cycle is accommodated in this gap.

By repeating the above steps, a plurality of molded body bodies 26a can be stacked on the stack guide 16a5.

<Post-process>
In the post-process, the resin panel 1 is formed by taking out the molded body body 26a on the stack guide 16a5 one by one, removing the small burrs 26e, and removing the fine burrs remaining on the parting line PL. obtain. This step can be carried out by the operator 21.

1: Resin panel 2: Resin molded body 3: Core material 3a: Base, 3a1: Recess, 3b: Base, 3b1: Recess, 3c: Reinforcing member, 3c1: Upper wall, 3c11: Protrusion, 3c2: Bottom Wall, 3c21: Protrusion, 3c3: Pillar part, 4: Skin material, 5: First manipulator, 5a: Transport stand, 6: Second manipulator, 6a: Mounting stand, 7: Member supply line, 8: Positioning device, 8a : Positioning table, 8b: Locking part, 8b1: First locking part, 8b2: Second locking part, 8c: Rotating mechanism, 8c1: Base, 8c2: First rotating member, 8c3: Second rotating member, 8c4: 1st rotation shaft, 8c5: 2nd rotation shaft, 8d: pedestal, 9: insertion device, 9a: base, 9b: suction pad, 9c: female type holding part, 9c1: female type protrusion, 9c11: shaft part, 9c12: swelling part, 9c13: concave part, 9c2: cylinder part, 9c3: base, 10: molding machine,
12: Holding device, 13: Holding device, 13a: Conveying line, 13b: Holding base, 13b1: Base, 13b2: Connecting member, 13b3: Arm, 13b4: Rotating shaft, 13b5: Rotating shaft, 13c: Rotating mechanism, 13c1: Base, 13c2: 1st rotating member, 13c3: 2nd rotating member, 13c4: 1st rotating shaft, 13c5: 2nd rotating shaft, 13d: Conveyor stand, 13e: Holding mechanism, 13e1: Base, 13e2: Rod, 13e3: Holding part, 13eb: Lower holding mechanism, 13ec: Central holding mechanism, 13eu: Upper holding mechanism, 13f: Holding surface, 13f1: Holding surface, 13f2: Holding surface, 13f3: Holding surface, 13g: Lower burr plate, 13h : Upper burr plate, 14: Inspection device, 14a: Weighing table, 14b: Weighing device, 14c: Sensor, 14d: Elevating device, 14d1: Base, 14d2: Rod, 15: Press device, 15a: Lower wall, 15b: Top Wall, 15c: Pressurizing device, 15c1: Base, 15c2: Rod, 16: Stacking device, 16a: Cylinder unit, 16a1: 1st base, 16a2: 1st rod, 16a3: 2nd base, 16a4: 2nd rod , 16a5: Stack guide, 17: Burr loading device, 17a: Burr receiving, 17a1: Bottom wall, 17a2: Side wall, 17b: Enclosure, 17b1: Back wall, 17b11: Loading port, 17b2: Side wall, 18: Crusher,
20: Manufacturing system, 21: Operator, 22: Core material transfer table, 23: Skin material transfer table, 24: Head, 24a: Base, 24a1: Member mounting surface, 24b: Suction pad, 24b1: Suction surface, 24c: Needle Gripper, 24d: male type holding part, 24d1: male type protrusion, 24d11: shaft part, 24d12: bulging part, 24d2: tubular part, 24d3: base, 24e: reinforcing member positioning mechanism, 24e1: first base, 24e2: 1st rod, 24e3: 2nd base, 24e4: 2nd rod, 25: sensor, 26: molded body, 26a: molded body body, 26b: large burr, 26bb: lower burr, 26bc: central burr, 26bu: upper burr , 26c: cutting line, 26cc: lower line, 26cl: left line, 26cr: right line, 26cu: upper line, 26d: molded product, 26e: small burr, 26f: parting line, 26fb: lower line, 26fl: left Line, 26fr: Right line, 26fu: Top line, 26g: Identification shape, 26h: Fold, 27: Head, 27a: Base, 27b: Adsorption pad, 27c: Imaging unit, 27d: Cutter, 28: Conveyor, 29: Feed Device, 29a: base, 29b: rod, 29c: tip,
61: Raw material resin, 61a: Molten resin, 62: Hopper, 63: Extruder, 63a: Cylinder, 64: Sheet forming device, 67: Accumulator, 67a: Cylinder, 67b: Piston, 68: T-die,
71: 1st mold, 71b: inner surface, 71d: pinch-off part, 71e: male mold protrusion, 71f: main body part, 71f1: protrusion, 71f1l: left line protrusion, 71f1r: right line protrusion, 71g: movable part, 71g1: Protrusion, 72: 2nd mold, 72b: Inner surface, 72d: Pinch-off part, 73a: 1st resin sheet, 73b: 2nd resin sheet, 75: Connecting pipe, 77: Connecting pipe, 78: Lower burr holding device PL: Parting line

Claims (4)

It is a method of manufacturing a structure.
It has a molding process, a holding process, a separation process, and a discharge process.
In the molding step, a molded body is formed and
In the holding step, the molded body is held by the holding table in a state where the holding surface of the holding table is erected.
The molded body is configured by connecting the molded body body and burrs.
In the separation step, the molded body is separated from the molded body, and the burr is left on the holding table.
In the discharge step, a method of discharging burrs placed on the holding table toward a burr receiver by tilting the holding table. The method according to claim 1.
A method in which the holding step, the separating step, and the discharging step are carried out on the same straight line. The method according to claim 1 or claim 2.
The holding table is supported by a rotation mechanism configured to be rotatable around the first rotation axis.
A method in which the holding table is rotated by the rotating mechanism at the time of transition from the holding step to the separation step and at the transition from the separation step to the discharging step. The method according to claim 3.
The rotation mechanism is configured to be movable along a transport line extending perpendicular to the first rotation axis.
A method in which the rotating mechanism is moved along the transport line between the holding step and the discharging step.

Images