WO2017142470A1 - Procédé et système de machine pour commander une opération industrielle - Google Patents

Procédé et système de machine pour commander une opération industrielle Download PDF

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Publication number
WO2017142470A1
WO2017142470A1 PCT/SE2017/050153 SE2017050153W WO2017142470A1 WO 2017142470 A1 WO2017142470 A1 WO 2017142470A1 SE 2017050153 W SE2017050153 W SE 2017050153W WO 2017142470 A1 WO2017142470 A1 WO 2017142470A1
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WO
WIPO (PCT)
Prior art keywords
machine
metal working
working process
process parameters
optimum operation
Prior art date
Application number
PCT/SE2017/050153
Other languages
English (en)
Inventor
Magnus NORBERG OLSSON
Original Assignee
Tomologic Ab
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from SE1651338A external-priority patent/SE545056C2/en
Application filed by Tomologic Ab filed Critical Tomologic Ab
Priority to KR1020187027261A priority Critical patent/KR20180118695A/ko
Priority to EP17753583.8A priority patent/EP3417349B9/fr
Priority to EP22152080.2A priority patent/EP4006665A1/fr
Priority to US15/999,482 priority patent/US11103909B2/en
Priority to ES17753583T priority patent/ES2910799T3/es
Priority to JP2018544063A priority patent/JP7113749B2/ja
Priority to CN201780019219.8A priority patent/CN109074047B/zh
Publication of WO2017142470A1 publication Critical patent/WO2017142470A1/fr
Priority to US17/238,157 priority patent/US20210237136A1/en

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Classifications

    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q10/00—Administration; Management
    • G06Q10/04—Forecasting or optimisation specially adapted for administrative or management purposes, e.g. linear programming or "cutting stock problem"
    • G06Q10/043—Optimisation of two dimensional placement, e.g. cutting of clothes or wood
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K15/00—Electron-beam welding or cutting
    • B23K15/0046—Welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
    • B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/20—Bonding
    • B23K26/21—Bonding by welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/36—Removing material
    • B23K26/38—Removing material by boring or cutting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
    • B23K31/12—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to investigating the properties, e.g. the weldability, of materials
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
    • G05B19/4093—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by part programming, e.g. entry of geometrical information as taken from a technical drawing, combining this with machining and material information to obtain control information, named part programme, for the NC machine
    • G05B19/40937—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by part programming, e.g. entry of geometrical information as taken from a technical drawing, combining this with machining and material information to obtain control information, named part programme, for the NC machine concerning programming of machining or material parameters, pocket machining
    • G05B19/40938—Tool management
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/35—Nc in input of data, input till input file format
    • G05B2219/35019—From product constraints select optimum process out of plurality of DTM means
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P80/00—Climate change mitigation technologies for sector-wide applications
    • Y02P80/40—Minimising material used in manufacturing processes
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Definitions

  • the present invention relates to a method, an industrial machine system, a computer program product and a non-transient computer-readable medium for selecting optimum operation performance criteria for controlling an industrial machining operation, such as a sheet metal working process.
  • the industrial machine systems are controlled by means of a CNC (Computerized Numerical Control) unit, an NC (Numerical Control) unit, a PLC (Programmable Logical Control) unit and/or related sensing and processing equipment that together serve to provide instructions to an actuator system to perform required movements in order to execute intended industrial operations.
  • the machine system further comprises a machine controller, which is essentially a computer having a processor and a conventional operating system such as Windows or Linux configured to give instructions to the CNC/NC/PLC unit based on machine controller instructions, such as G-code or XML.
  • the machine controller includes or is connected to an HMI (Human-Machine Interface), and is configured to read programs and to gather process parameters so as to yield complete instructions to the CNC/NC/PLC unit for execution by the actuator system comprised in the machine.
  • HMI Human-Machine Interface
  • both the CNC/NC/PLC unit and the machine controller are physically included in the industrial machine, and the industrial machine forms an independent and self-contained industrial machine system wherein the machine controller forms an essential and physically connected part of the machine.
  • a CNC system may be defined so as to comprise a machine tool, herein referred to as a machine, a part program, which is a detailed set of commands followed by the machine, and a machine controller (or machine control unit), which is a computer that stores the program and executes its commands into actions by the machine tool.
  • a machine tool herein referred to as a machine
  • a part program which is a detailed set of commands followed by the machine
  • a machine controller or machine control unit
  • Management, control and monitoring of operations performed by an industrial machine need expertise and experience from a machine operator as well as software-based support systems to work out.
  • the program needs to be based both on a set of predetermined principles, such as the calculation of operating sequences based on optimization techniques or shortest path principles, but also an operator's know-how of what will be the best sequence from a more practical point of view.
  • Variables to consider and control may be related to materials properties, logistics and of course to the actual geometries, shapes, dimensions and order in which products are to be produced.
  • Prior art technology discloses the establishment of machining or cutting programs which are based on the principle that of single parts are produced as individual units.
  • a wide variety of conventional production methods are used for this purpose, such as cutting, punching and/or pressing.
  • production metrics to be applied for the cutting, punching and/or pressing operation are defined in advance. Individual definitions are made for each part and applicable safety distances between adjacent parts are defined for each individual part.
  • the so-called common cut technology has evolved as an improvement to the more conventional cutting techniques.
  • the underlying technique for the common cut technology is based on dividing a workpiece by cutting two adjacent parts, the parts being separated by a distance corresponding to the width of a cut of the cutting beam.
  • careful consideration must be made, when positioning shapes to be divided from each other, to the width of a cut of the cutting beam, given the prerequisites for that particular cutting operation.
  • Prerequisites for a cutting operation are to be determined already in connection with initial preparation for and positioning of shapes to be separated along the cutting path.
  • careful planning of a common cut machining process is crucial.
  • the above described common cut technique could also be applicable to for example punching or pressing operations, provided that the common cut technique allows parts to be separated from each other without causing damages or deformations, and does not cause the dimensions and quality of the produced item to exceed acceptable tolerances according to specification.
  • International patent publication WO 2011/042058 discloses a method and a system for machine cutting several parts out of a piece of material using a beam cutting technology.
  • a set of controlling rules and variables are applied for forming a cluster of parts with free form shapes, the parts being positioned so close to each other so that only the thickness of one cut from the cutting beam is found between adjacent parts whenever the shape of the parts allows it. Since the introduction of free form shapes in cutting operations, the market has quickly realized that the technology has a potential to noticeably increase productivity in sheet metal working processes.
  • One of the first advantages noted from free form cutting is the saving of valuable process time during cutting operations, which is one of the top priorities for competitiveness in production industry.
  • Another advantage provided by the free form shape cutting is that it enables the shapes subjected to cutting to be arranged in a tighter pattern, thereby significantly reducing material waste, which is of benefit both from an industrial and an environmental perspective.
  • a related problem that needs to be at least considered when setting up and performing an industrial machining operation is the large number of dynamic variables that may have an influence on the operation. Some of those variables may otherwise adversely affect the efficiency, precision, quality and productivity of the industrial machining operation, whether the variables are related to logistics, materials properties, production quality, presently used tooling, available tooling or operators' needs.
  • the optimum performance criteria calculated for the process model according to the above, result in a set of requirements which are transformed into operational instructions for controlling of an industrial machine.
  • the control is typically executed by means of an industrial machine program, comprising a set of operational instructions that instruct an actuator system to execute machining operations.
  • the present invention uses information retrieved from multiple sources, and stores such information in a way that it is made available for use in connection with subsequent machining operations.
  • the invention makes it possible to design and make available new or additional tools or tool geometries as required by the specific machining operation that is to be executed.
  • the method for selecting optimum operation performance criteria for a metal working process comprises a process model, which is dynamically monitored and controlled.
  • the method for selecting optimum operation performance criteria for a metal working process comprises a process model, which is monitored and controlled in real-time to allow for dynamic adjustments in the process.
  • the set of requirements to be used for controlling the metal working process can be provided as recommendations to an operator, who in turn may apply the set of requirements.
  • the requirements may be applied with partial or no operator involvement.
  • the method for selecting optimum operation performance criteria for a metal working process further comprises the step of:
  • process parameters from multiple sources relating to the metal working process, such as production order, product geometry and predefined tolerances, required metal working operations, required tooling configuration, stacking pattern of produced items, and/or process parameter data from previous operations,
  • performance variables from different sources relating to the metal working process, such as determined tolerances of produced items, process time, tooling availability, machine availability, material availability, tooling lifetime, material removal rate, operator working environment, order stock, delivery time, required pressing position and/or performance variable data from previous operations and/or performance variable data for subsequent operations,
  • ERP enterprise resource planning
  • the plurality of process parameters are typically retrieved from different sources of information, and a central computer (alternatively machine controller or computing system) may be configured such that it is connected or at least is connectable to these sources of information.
  • a central computer alternatively machine controller or computing system
  • the sources of information may be very different and could be considered to be end-points in the machining system.
  • Process parameters are predefined parameters which typically relate to what is to be produced, what is the order size, which are the optimum machining operations to be performed so as to achieve predefined product geometries? Also optimum tooling utilisation for machining and predefined tolerances of the produced items are process parameters. Performance variables on the other side are data relating to the hypothetical result should other than optimum machining operations or optimum tooling configurations be used. It is also measured data from previous and/or currently and/or subsequent performed operations, which can be used as a basis for decision making, when a number of different variables are to balanced and the machining process is to be optimised. Optimisation can be made based on any variable, such as for example production cost, production time, quality and product precision, operator working conditions, material waste or any combination thereof.
  • An example of the advantages of the invention is that tooling configuration to be exchanged between subsequent operations can be minimised. Experiences from prior operations can be used to determine whether a present tooling configuration is sufficient for achieving a particular geometry, and whether the produced geometry will be within acceptable tolerances. Another example is that precision can be increased by avoiding tooling contacts with certain areas on items produced which may contain defects.
  • tools and/or produced items are embedded with electronics, software, sensors and/or network
  • This connectivity often referred to as Internet of Things (loT)
  • LoT Internet of Things
  • the computer system may then have instant access to updated information on which tools can be used and which cannot, for example due to being used for another machining operation of higher priority.
  • a surveillance unit such as a camera or other image capturing means, to detect presence and nature of various defects and/or visual attributes, bulges and/or other asymmetrical attributes created by a bending operation, so as to avoid their interference or any effects derivable from symmetry imperfections when stacking parts.
  • Detailed information on those defects or visual attributes are retrieved, stored and made available when determining a set of requirements to be applied in a process model for a subsequent metal working process.
  • the pressing position or required pressing coordinates are used to precisely determine whether the pressing pressure exerted is sufficient to reach the predefined position, i.e. a predefined coordinate in space, to which the tools is intended to reach.
  • Retrieving and using process parameters also enables an increase in precision by avoiding tooling, clamping and gripping contacts with less defined areas on items produced.
  • a business management system which is available in virtually any industrial company, workshop or enterprise, is used to manage and control the industrial machining system.
  • this management system for logistics, production, inventories, maintenance, sales, etc., i.e. one or more systems in which all information is available and the dynamics of the business operations conducted are reflected, all aspects influencing the productivity and with relevance to its customers into consideration can be taken into consideration.
  • Such information may even include order availability, customer priorities and pricing information, besides all information related to material properties, batch number, requested dimensions, shapes, tolerances, locations and various machining parameters.
  • the present invention hence brings together information that is, or could be, contained in an enterprise resource planning system with all requirements and the huge potential efficiency enhancements of modern machining systems, so as to significantly improve the productivity in certain segments of the production industry.
  • the dynamic monitoring and control allows the producer to decrease batch sizes during production and in a near future allows the producer to immediately respond to short-lived variations in the demand.
  • the present invention provides at least a first step towards the industrial vision of production of unique items and on demand.
  • Figure 1 is a flow chart that depicts an optimisation of an operational sequence of an industrial machine system by monitoring, controlling and adjusting the sequence.
  • Figure 2 graphically illustrates an industrial machine system according to one embodiment.
  • FIG. 3 displays another embodiment of an industrial machine system according to the invention.
  • the present invention relates to identification of part geometries, generation of a program for controlling an industrial machine system. It also concerns configuration of an industrial machine system, in particular an industrial machine system for metal working, such as a punch press, press-break or bending machine. Combinations of punch presses and beam cutting machines are also conceivable for use, since such combinations are suitable also for milling and turning operations, besides cutting. Moreover, the invention relates to automation equipment and utilisation of process data obtained during previous machining operations, which data is used as input when planning, configuring, executing and managing a subsequent machining operation.
  • Sheet metal working is a generic term applicable to machining operations generally.
  • Cutting which is one of the comprised types of operations, is in this context to be construed as a machining operation executed by any of a variety of industrially applicable technologies, including cutting by means of technologies as laser, flames, plasma, water jet, ion, air as well as cutting by pressing, punch pressing and press-breaking.
  • Milling, drilling and turning operations also belong to sheet metal working, provided the operations relate to machining of sheet metal.
  • Material-oriented properties that vary between subsequent operations are material quality, material compositions, size, shape and production batches that each clearly influences the result and precision achieved during a machining operation, whether it is bending, punching, cutting, milling, drilling, turning etc.
  • One of the mentioned influential properties is the sheet rolling direction, a variable that is dependent on the prior logistics operations of the material.
  • the sheet rolling direction may have a significant impact on the result of a bending operation.
  • Another property is rotation of parts and mirroring of the sheet metal, whereby rotation and mirroring of identical parts in different directions may have an influence on bending angles for otherwise identical parts. Bending angles may vary as much as by several degrees between two subsequent bending operations.
  • micro-joints are generated by closing the cutting path which surrounds the geometry of the part.
  • common cutting techniques and clustering of free form shapes may generate different types of marks from tangential points, different types of lead-ins and different types of micro-joints that occur between parts and the surrounding skeleton or between adjacent parts.
  • All of the mentioned marks, lead-ins, micro joints can be seen as part defects or visual attributes. They are all departures from the original drawings, and provided their existence and positions are known in advance of a machining process, the present invention provides a way to completely avoid them and or at least to alleviate any negative influence from them.
  • a first machine operation may have left defects and/or visual attributes, such as hardened or irregular surfaces etc., which makes it even more important for a subsequent machine operation to avoid them in order to protect applicable tooling from being damaged and thus increase its lifetime.
  • Segments which are not allowed to comprise any part defects or visual attributes may be marked. This way of marring, managing and avoiding imperfections is called tagging. As a result of marking segments to be avoided, the industrial machining system will not place any lead-ins, micro joints, tangential points or other part defects or visual attributes on these segments. This allows for enhanced part quality and process reliability all through the value chain but also results in increased volumes of scrap, i.e. materials waste. Scrap is undesired and would limit the availability of techniques as common cut or clustering of free form shapes, which would otherwise be a means to enhance the productivity of industrial processes. Tooling, i.e. a set of suitable tools for executing a bending program, or other machining program, can be chosen both manually or automatically.
  • a commonly used method for placing the workpiece in a precise position before executing for example the bending operation is to position axes of actuators as required.
  • Back gauge, clamping mechanisms or fixtures are used to more accurately position and support a workpiece before the bending operation is executed. All of the above machine configurations and support arrangements generate data, which is collected. Also cutting heads, nozzles, lenses and related optics equipment relating to machining operations generate data that can be collected, provided as feedback and thus taking part in an optimisation of machining operations.
  • Bending angles and/or back spring can be measured both manually and automatically by means of for example laser, optical, mechanics.
  • Automation units are configured to support an operator to move the workpiece so that sequencing and bending operations can be executed.
  • Processed parts are stacked manually and/or automatically after machining operations have been executed. Stacking is made prior to customer delivery according to a number of guiding principles, some of which are related to operational efficiency, some of which are related to logistics and some of which are related to customer needs.
  • the present invention relates to generation of a machining process, such as a program for punching, combinations of punching laser, milling, drilling, turning and/or bending, and takes into consideration information from the previous operation in sheet metal working.
  • the program optimises tooling configuration, through minimising required tooling exchange from a previous operation, minimising the number of tools required and the movements of tools.
  • the program also minimises the motions required so as to reduce cycle time, applicable for an operator and/or automated process.
  • the effort required for an operator to move a workpiece is also considered, which means that the shortest path does not always require the least effort.
  • the machining program could be made directly on the machine or disconnected from the machine depending on its configuration.
  • Conceivable is to allow collisions to be simulated manually or automatically before executing the program on the machine.
  • Figure 1 is a flow chart that depicts an optimization of an operational sequence in an industrial machine system or a manufacturing support system, possibly remote in a central computer which is connected or at least is connectable to multiple sources of data.
  • the system may be configured to provide support for business operations relating to design- and construction processes (including the option of parametric design), selection of material, purchasing, logistics etc., by inputting desired parameters followed by modifying and presenting the optimum performance criteria.
  • the sequence starts (S10) in that an operator or client either manually or automatically inputs (S20) desired parameters relating to a product to be machined or evaluated.
  • This input of desired product parameters can be made at any location.
  • an application (app) developed for a mobile terminal, such a so-called smartphone, is used as a tool for realizing the input of desired parameters.
  • This app may then be provided to all stakeholders along the value chain, for example designers, purchasers, logistics professionals,
  • the computing system generates (S30) resulting operational data based on the desired process parameters.
  • a first step the process model is provided (pre-loaded) (S20) with process parameters relating to a previous sheet metal working operation.
  • identification S30 is made of clamping mechanism, gripping configurations and tooling locked up, i.e. currently applied settings, configurations and tools in the machine.
  • next step analysis is made of whether the current tooling configuration can be used to effect a complete machining operation of next batch for production (S40), such as a bending operation of parts for subsequent production. An evaluation is also made of whether the current tooling configuration could be improved given an available workpiece for production and its process parameters.
  • S40 next batch for production
  • the product geometry is analysed, so as to determine whether an adjustment to the geometry within acceptable tolerances, would be possible to produce given the current set of tooling.
  • the tooling available for exchange is analysed, so as to determine whether the original or alternative product geometries, as mentioned still within acceptable tolerances, would be possible to produce given the available tooling.
  • it is hence determined whether to keep current tooling configuration, adjust the product geometry within tolerance boundaries or exchange at least one tool to execute the currently applicable machining operation (S50, S60, S65). Calculation is also made of the optimum tooling configuration based on tooling availability.
  • the determination of whether the current machine configuration enables production of an item according to its process parameters (S40) also includes determination of other enabling requirements besides the tooling configuration.
  • Examples of the requirements may be missing spare parts, missing tooling, need for maintenance, material quality, shape, dimension and/or material of a part to be manufactured.
  • Process parameters and performance variables relating to the requirements are stored in the computer system, the computing system and/or a central computer which is connected or at least is connectable to a plurality of sources of data, and in connection with the machine.
  • the requirements relating to a process to be executed may be responded to by issuance of a purchase order or operator recommendation. Such a purchase order may be issued automatically, i.e.
  • a supplementary production order may be placed without direct operator involvement so as to meet customer demands on quality and precision in the delivery.
  • Parts are identified before the machining operation by using any known identification method, such as computer vision or other image capturing technology, to identify geometries, defects and/or engraved, marked or other visual attributes of parts to be machined.
  • identification method such as computer vision or other image capturing technology
  • Back gauge, clamping mechanism and/or fixture are configured to avoid defects and/or visual marks from the previous operations from coming in direct contact with the back gauge. This allows the workpiece to be positioned correctly and in direct contact with its support when executing bending operations. Moreover, bending pressure is adapted so as to generate correct bending angles based on data from prior operations, by means of using a bending angle measuring system which is provided with feedback from prior operations, whereby every bend produced has an angle within acceptable tolerances.
  • required attributes described above i.e. composition, batch, sheet rolling direction-rotation, part rotation, part mirroring, clustering, common cut, lead-ins, micro joints, etc. are continuously monitored.
  • process parameters i.e. bending position, bending pressure, crowning data, angle measurement data, back spring measurement data, positions of back gauge, clamping mechanisms and fixture, tools radius compensation, tooling condition etc.
  • crowning is here meant a technique used to compensate for deviations along a bending line.
  • Parts may be visually inspected after the bending operation to identify geometries in combination with defects, visual attributes, such as bending lines, bulges and/or asymmetries created by the bending operation.
  • visual attributes such as bending lines, bulges and/or asymmetries created by the bending operation.
  • stacking of parts may be made to avoid placing defects between parts thus affecting the symmetry of the stack.
  • the computing system which is be connected to or at least is connectable with plural sources of data, selects (S40) at least one optimization technique to define a function, a function which comprises the desired process parameters.
  • S40 selects at least one optimization technique to define a function, a function which comprises the desired process parameters.
  • S50 generation of a function for optimization by using the desired process parameters as a basis to define ranges for performance variables along with ranges for process parameters.
  • the generated function for optimization is applied (S60) whereby optimum operation performance criteria can be determined for the process model including process parameters and performance variables to obtain a set of requirements to be used for controlling the metal working process.
  • the resulting operational data is compared (S70) with the optimum operation performance criteria, and in case there is a difference, and the optimum performance criteria seems to provides a performance advantage to the operator or client, the result is presented (S80) to a decision-making entity.
  • This decision-making entity whether being a human operator, a computerised, fully or semi- automated service layer, is allowed to modify (S90) the desired process parameters based on the presented optimum operation performance criteria for the metal working process.
  • the decision-making entity may also be realized in the form of an application (app) for a smartphone, preferably the same or an app similar to the one mentioned in connection with the step of inputting desired parameters.
  • the decision-making entity decides to modify process parameters comprised in the presented information (Yes)
  • the proposed operational sequence is adopted by the industrial machine system.
  • the decision-making system decides not to accept the proposal (No)
  • the sequence continues in that the originally generated operational data is applied (S100). Whichever decision is made, the sequence continues to the starting point (S10) or end point (S110).
  • Modified data may further be used in different applications such as CAD, CAM, ERP, MES, CRM, Sourcing management etc.
  • the present invention is also applicable within areas such as purchasing and optimization of machine performance criteria, criteria which may be defined as instructions and/or a program of instructions for the control an industrial machine, such as a CNC machine tool.
  • Figure 2 graphically illustrates a first embodiment of the invention.
  • the system comprises a machine 1, which may be a machine for beam cutting (2- or 3-dimensional), punching, punch pressing, press-breaking, bending, gluing, sewing, tape and fibre placement, milling, drilling, turning, routing, picking and placing and combinations of such machines.
  • Beam cutting includes techniques such as laser, welding, friction stir welding, ultrasonic welding, flame and plasma cutting, pinning and sawing.
  • the machine comprises an actuator system 2 for performing an industrial operation.
  • the actuator system comprises at least one actuator, i.e. a motor for linear or rotational movement.
  • the actuator system is configured for performing two-dimensional or three-dimensional movements of an operational part of the machine and a workpiece relative to each other.
  • the actuator system is controlled by an actuator controller 3 in the form of a CNC/NC/PLC unit and/or related sensing and processing equipment.
  • the actuator controller controls the actuator on a low level, i.e. by sending low level control commands for the actuation of the actuator system.
  • the actuator system is connected to the actuator controller via a machine internal communication network 4, e.g. including a communication bus.
  • the machine optionally comprises other systems, such as a sensor system 10 for sensing various processing parameters of the machine and other controllers 11 for processors, networks, communication links or other computing devices for transmitting data and making decisions. These systems may also be connected to a machine common internal
  • the machine controller may be further configured to remotely control the actuator system of the machine in response to the sensor data.
  • the CNC/NC/PLC unit and/or related sensing and processing equipment as well as the mentioned machine controller may be physically attached to or otherwise included in the industrial machine.
  • the industrial machine then forms an independent and self-contained industrial machine system, wherein the machine controller forms an essential and physically connected part of the machine.
  • the machine may also comprise a communication client 5 connected to the actuator controller 3 for establishing communication with a computing system 6 in connection with the machine, when configured according to the remote alternative.
  • the communication client is then a functional unit which enables the machine or any sub-component of the machine to communicate with the machine controller.
  • the computing system in connection with the machine may be a cloud-based computing system connected to the internet.
  • a centrally arranged computer in connection with or connectable to a plurality of data sources is an alternative embodiment.
  • the communication client 5 and the computing system in connection with the machine may be configured to establish secure communication 7 with each other over the internet, for instance by initiating encrypted communication by HTTPS/TSL or by establishing a VPN (virtual private network). Alternatively, the communication may be established over a firewall or a proxy server 8.
  • any sub-component of the machine such as the actuator controller 3, may be configured to connect to the computing system 6 in itself, or alternatively to the mentioned central computer with access to multiple data sources, but as mentioned both remote and integrated configurations are equally applicable for this purpose.
  • the mentioned computing system 6 in connection with the machine comprises a machine controller 9, wherein the machine controller may be remotely connected to the machine, and wherein the machine controller may be configured to control the actuator system of the machine remotely via the actuator controller by modifying operational parameters of the actuator controller.
  • the machine controller 9 is hosted in a virtual machine in the remote computing system 6. In that way the machine controller resource may be exploited in an efficient way.
  • the machine controller may e.g.
  • the machine controller is connected to a HMI (Human-Machine Interface) unit 12 which may be remotely connected to the machine controller via an internet connection 13 and in another embodiment is integrated with the machine. Either way, an operator of the machine may supervise and control the operation of the machine from a remote location, e.g. connected to the internet.
  • the HMI unit 12 and/or remote computing system 6 may be configured to require user identification of an operator, e.g. by requiring passwords or other identification means.
  • an actuator system 2 comprising actuators for performing machining operations is included.
  • An actuator controller 3 is part of or connected to the actuator system 2.
  • the actuator controller is configured to receive instructions from the remote machine controller and execute instructions block by block in a closed loop system. Each task performed by an actuator is hence monitored and after a completed sub-operation, the actuator will perform the next sub-operation until a whole operation is completed. This means that the operation of the actuators of the machine is controlled by the actuator controller on a low level.
  • the actuator controller typically includes a memory and a processor in order to save and execute instructions and to log data.
  • the actuator system does not involve a conventional machine controller or HMI.
  • the actuator system of the machine is hence dependent on receiving instructions from the remote machine controller.
  • a sub-set of work instructions may be a part of a complete machine operation, but at least involves enough information for the actuator system to perform a part of a complete operation.
  • the operation is preferably performed step by step in a closed loop system within the machine.
  • the machine is only furnished with simple functions such as an emergency stop button and an on/off button. Other than that the machine is dependent on commands from the remote machine controller to operate.
  • the machine controller is physically located remote from the machine, typically in the cloud. The monitoring of an ongoing process, loading of instructions, modification of instructions and creating new instruction may only be made at the remote machine controller.
  • the inventive machine controller corresponds to a conventional machine controller, only it is not a physical part of the machine but remote connected to the machine.
  • the instructions monitored and controlled by the machine controller and the interconnected HMI include operational parameters such as cutting velocity, cutting depth, pressure and so on.
  • the machine controller is not part of the closed loop system of the actuator controller. Hence, unless new instructions are sent from the machine controller, the actuator system at the machine will conclude a fully received operation instruction without awaiting further instructions, unless specific instructions to conclude or alter the operation are received from the machine controller. Typically though, instructions are only provided for a full operation and new instruction will therefore only count for subsequent operations, not ongoing operations. This may be set as a safety arrangement but is up to the operator to decide which type of operational security should be implemented.
  • the machine controller is configured to send instructions, instruction per instruction, or several instructions in a batch system. Any conventional manner of sending information may be utilized.
  • the machine controller is further configured to receive information and make decisions based on said information. For example, the machine controller may act on feedback data and make decisions and/or send new instructions based on said feedback.
  • the inventive system provides for a possibility of remote controlling of an industrial machine, without risking that commands are lost as a consequence of bad communication due to for instance latency in the internet connection. This is made sure e.g. because an operation is received and acknowledged in full at the actuator controller.
  • the machine comprises a surveillance unit 14, such as a camera, video camera or other image capturing means, for monitoring operations by the machine.
  • the surveillance unit is connected to the remote computing system 6 via the communication client 5 and configured to provide operational information to the remote computing system.
  • the operational information is processed and transmitted to the HMI 12.
  • the machine controller is configured to receive a machine program from a CAD/CAM system or by manual entry from an operator, e.g. via the HMI unit 12.
  • the remote computing system is configured to monitor an operational parameter of the machine, and disable the remote control of the actuator system of the machine by the machine controller when the operational parameter exceeds a threshold value.
  • an operational parameter may be the operating time, the number of operational cycles performed by the machine etc.
  • the operational costs and the use of the machine may be controlled and limited by limiting access to the machine controller.
  • the remote computing system is configured to collect machine and/or production data and transfer the data to another system (not shown) for data analysis and/or optimization.
  • the machine data may be used to e.g. optimize the supply chain (purchase, manufacturing, distribution), the demand chain (marketing, sales, service), machine maintenance or for other big data applications.
  • the surveillance unit may also be configured for monitoring produced items and their various properties, including their tolerances.
  • Computer vision is another term used in the industry for this identification of properties related to geometry.
  • tolerances is meant material properties, such as hardness, toughness, size, shape, product geometries, such as radii, angles and dimensions, and production defects, such as, bulges, bending lines, pressure deformations and/or other visual attributes.
  • the surveillance unit may further be connected to the computing system 6 in connection with the machine, via the communication client 5 and configured to provide operational information to the computing system.
  • the computing system in connection with the machine is configured to monitor an operational parameter of the machine, and disable the remote control of the actuator system of the machine by the machine controller when the operational parameter exceeds a threshold value.
  • an operational parameter may be the operating time, the number of operational cycles performed by the machine etc.
  • the computing system is configured to collect machine and/or production data and transfer the data to another system for data analysis and/or optimization.
  • This system may be an enterprise resource planning system (ERP) of manufacturing execution system (MES) of any kind.
  • ERP enterprise resource planning system
  • MES manufacturing execution system
  • the machine data may be used to for example optimize the supply chain, i.e. purchase, manufacturing and distribution; the demand chain i.e. marketing, sales and service; and maintenance of the machine or its integrated or remote parts.
  • Machine data may also be made available for other systems, such as big data applications designed merge data and draw conclusions based on very large amounts of information.
  • Figure 3 displays an alternative embodiment of an industrial machine system according to the invention.
  • the industrial machine system differs from what is described in relation to figure 1 in that the machine does not comprise an actuator controller.
  • the actuator controller 3' is physically disconnected to the machine and comprised in the computing system 6 in connection with the machine.
  • the computing system is connected to the machine via one or more data lines 7, e.g. over the internet, which may be encrypted.
  • the machine 1 comprises at least one communication client 15 for establishing communication between the machine and the computing system 6 in connection with the machine.
  • This communication client 15 is connected to the actuator system 2 of the machine, and thus called the actuator client.
  • the client is configured to send and receive low level communication from the actuator controller to the actuator system.
  • the machine may optionally comprise a sensor
  • the communication client 16 for communicating any sensor data from the sensor system 10, and any further controller clients 17 for communicating with other controllers 11 in the machine. Similar to what is shown in relation to figure 2, the communication between the machine and the computing system in connection with the machine may be the established over a firewall or a proxy server.
  • Information relating to the production process generally comes from different sources, e.g. an ERP/MES, the machine, loT information, CAD/CAM and one or more surveillance units.
  • the information collected by means of a central computer which is configured as an intermediate means, that is situated in-between various end-points.
  • the end- points are typically sources of information that may or may not influence a production process, and are comprised of for example the previously mentioned ERP/MES, the machine, loT information, CAD/CAM and surveillance units.
  • the central computer may either be a general purpose computer or the computer that is configured to function as the machine control.
  • the central computer will always be connected, or is connectable, to at least two end-points comprising data, in order to obtain information subject to optimization. That is believed to be a minimum requirement in order to carry out and fully accomplish a non-sequential optimization process on multiple variables.
  • Several methods of optimization may be used, based on combinatorics, dynamic variation,
  • the present invention utilizes non-sequential optimization, which is a numerical process or method that is neither sequential nor linear as compared to traditional processes.
  • steps in a production process may be subject to optimization.
  • One example is geometry of parts to be produced, a geometry that may be modified to reduce tool changes
  • another example is scheduling jobs may be altered to reduce setup time provided that information is retrieved from for instance a machine, a surveillance unit and/or from loT information sources
  • third and fourth examples are scheduling jobs that may be adjusted to reduce material changes, provided that information is gathered from at least two end-points, and information that can be read and reused from previous process steps, e.g. visual attributes via a surveillance unit or modification of tool combinations or the rotation of a part on its surface.
  • Other conceivable examples are to reconfigure machine tools, such as the back-gauge positioning, pressure, pressing position etc. or the ordering of tools, materials, maintenance, spare parts for reducing production disruptions.
  • One of the prerequisites to making this type of optimization is to allow retrieval of data from a variety and a plurality of sources e.g. ERP/MES, the machine and its configuration, loT information, CAD/CAM, surveillance unit. Information is then collected in and made available from the central computer in order to allow for optimization of several separate process steps in relation to their current status, including dynamic influences that are not controllable, since being dependent circumstances on out of reach, such as updates in a management system.
  • the present invention may also introduces control of the so-called modifiability and customizability in various end-points (data sources), such as ERP/MES, the machine and its configuration, loT information, CAD/CAM (both with respect to design and configuration) and at least one surveillance unit.
  • the present invention it is possible to change the materials specification as a measure to potentially reduce material and tool changes, the mandatory tolerance intervals and relevant ranges of strength and solidity.
  • Is may also be possible to schedule jobs to reduce material/tool replacement while keeping the delivery time. This allows communication with the customer so as to possibly allow the delivery time to be a variable influencing the price of the produced item.
  • two or more end points must be able to control in a non-sequential fashion, e.g.
  • the present invention is differentiated from traditional prior art process planning by means of MES systems of production scheduling that are configured to retrieve information from a local database. Those systems may even be based on the functionality that an operator keys in data on orders and delivery, which is followed by sequential scheduling.
  • the present invention is based on an entirely different level of optimization based on actual, even real time data, a central computer that retrieves, a computer that also in some cases may share information.
  • the central computer is connected or connectable to two or more end points, such as ERP, MES, CAD, CAM, machine, loT information sources, at least one CRM management system and/or surveillance unit.
  • the central computer may also be connected or connectable to other providers of information relating to multiple variables influencing production, such as materials, tooling, spare parts, maintenance, design, specification or customers of parts, constructions and/or products.

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Abstract

La présente invention concerne un procédé de sélection de critères de performance de fonctionnement optimal pour un processus de travail des métaux. Le procédé comprend l'étape consistant à développer un modèle de processus concernant des paramètres de processus pour une opération avec des variables de performance pour ladite opération, les paramètres de processus et les variables de performance pouvant être récupérés par l'intermédiaire de sources de données multiples intégrées, et à sélectionner au moins une technique d'optimisation pour définir une fonction, ladite fonction comprenant des paramètres de processus. De plus, le procédé comprend la génération de la fonction d'optimisation en utilisant des tolérances acceptables d'un produit à usiner en tant que base pour définir des plages de variables de performance conjointement avec des plages de paramètres de processus, et l'application de ladite au moins une technique d'optimisation à ladite fonction, les critères de performance de fonctionnement optimal étant calculés pour le modèle de processus incluant des paramètres de processus et des variables de performance pour obtenir un ensemble d'exigences à utiliser pour commander le processus de travail des métaux.
PCT/SE2017/050153 2016-02-19 2017-02-17 Procédé et système de machine pour commander une opération industrielle WO2017142470A1 (fr)

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KR1020187027261A KR20180118695A (ko) 2016-02-19 2017-02-17 산업 작동을 제어하기 위한 방법 및 머신 시스템
EP17753583.8A EP3417349B9 (fr) 2016-02-19 2017-02-17 Procédé et système de machine pour commander une opération industrielle
EP22152080.2A EP4006665A1 (fr) 2016-02-19 2017-02-17 Procédé et système de machine pour commander une opération industrielle
US15/999,482 US11103909B2 (en) 2016-02-19 2017-02-17 Method and machine system for controlling an industrial operation
ES17753583T ES2910799T3 (es) 2016-02-19 2017-02-17 Método y sistema de máquina para controlar una operación industrial
JP2018544063A JP7113749B2 (ja) 2016-02-19 2017-02-17 金属加工プロセスを最適化するための最適動作性能基準を選択するためのコンピュータ制御される方法、産業用機械システム、コンピュータプログラム製品及び非一時的コンピュータ可読媒体
CN201780019219.8A CN109074047B (zh) 2016-02-19 2017-02-17 用于控制工业操作的方法和机器系统
US17/238,157 US20210237136A1 (en) 2016-02-19 2021-04-22 Method and machine system for controlling an industrial operation

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SE1651338A SE545056C2 (en) 2016-02-19 2016-10-12 Method and machine system for controlling an industrial operation
SE1651338-4 2016-10-12

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CN110941873A (zh) * 2018-09-24 2020-03-31 波音公司 用于制造参数部件的系统和方法
WO2020069889A1 (fr) * 2018-10-01 2020-04-09 Trumpf Werkzeugmaschinen Gmbh + Co. Kg Procédé et dispositif d'usinage d'une pièce
RU2702387C1 (ru) * 2018-12-27 2019-10-08 федеральное государственное автономное образовательное учреждение высшего образования "Санкт-Петербургский политехнический университет Петра Великого" (ФГАОУ ВО "СПбПУ") Способ автоматизированной технологической подготовки операционных карт мелкосерийного машиностроительного производства
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CN114378408A (zh) * 2020-10-06 2022-04-22 无锡米普勒自动化设备有限公司 一种氩弧焊接机控制系统及控制方法
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