WO2010035650A1 - プレスラインの運転条件設定方法 - Google Patents
プレスラインの運転条件設定方法 Download PDFInfo
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- WO2010035650A1 WO2010035650A1 PCT/JP2009/066017 JP2009066017W WO2010035650A1 WO 2010035650 A1 WO2010035650 A1 WO 2010035650A1 JP 2009066017 W JP2009066017 W JP 2009066017W WO 2010035650 A1 WO2010035650 A1 WO 2010035650A1
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- press
- transport
- phase difference
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- setting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D43/00—Feeding, positioning or storing devices combined with, or arranged in, or specially adapted for use in connection with, apparatus for working or processing sheet metal, metal tubes or metal profiles; Associations therewith of cutting devices
- B21D43/02—Advancing work in relation to the stroke of the die or tool
- B21D43/04—Advancing work in relation to the stroke of the die or tool by means in mechanical engagement with the work
- B21D43/05—Advancing work in relation to the stroke of the die or tool by means in mechanical engagement with the work specially adapted for multi-stage presses
Definitions
- the present invention relates to a press line operating condition setting method. More specifically, the present invention relates to a method for setting operating conditions for a press line including a plurality of press machines and a plurality of conveying devices, and a method for setting operating conditions such as a lifting operation of these press machines and a conveying operation of a conveying device.
- a transport device for transporting a workpiece between the press machines is provided.
- a press line manufactures a product of a predetermined shape from a plate-shaped workpiece through a plurality of pressing processes by each pressing machine. Each press is assigned a different pressing process.
- the conveying device provided between the press machines moves the workpiece from the press machine that performs the previous press process to the press machine that executes the next press process for each press machine that moves up and down at a predetermined cycle. Transport. Therefore, it is necessary to set the conveying operation of the conveying device so as not to interfere with the upper mold of each press machine that moves up and down.
- Patent Document 1 discloses a method for setting the transport operation of such a transport device.
- a plurality of reference forms for the transport operation are prepared in advance.
- the start position and end position of the transport apparatus are designated. According to this setting method, it is only necessary to select the reference form and specify the start position and the end position of the transfer apparatus, so that the time required for setting the transfer operation of the transfer apparatus can be shortened.
- the present invention aims to provide a method for setting operating conditions of a press line that can improve the production cycle.
- the press line operating condition setting method of the present invention includes a plurality of press machines that press a workpiece by moving an upper die (for example, an upper die 22 described later) up and down relative to a lower die (for example, a lower die 21 described later).
- a press machine 2 described later and a plurality of transfer devices (e.g., a transfer apparatus 3 described later) that transfer workpieces along a predetermined transfer path (e.g., transfer path C described later) between these press machines.
- a control device for example, a control device 4 to be described later for controlling the periodic lifting operation of each press and the periodic transport operation along the transport path of each transport device.
- An operation condition setting method for setting a line speed for example, a later-described line SPM (for example, a later step) 3) of FIG. 3 and the transfer device so that the clearance (for example, ⁇ D1, ⁇ D2 described later) between the transfer device or the workpiece transferred by the transfer device and the lower mold is minimized.
- a conveyance path setting step for example, step S4 in FIG. 3 to be described later
- a processing speed setting step for setting a processing speed (for example, a press SPM to be described later) indicating the processing capability of the workpiece of the press machine. (E.g., step S6 in FIG.
- a phase difference setting step for example, step S7 in FIG. 3 to be described later for setting a phase difference (for example, phase difference ⁇ TH between transfer devices to be described later) of The phase difference between the lifting operation of each press and the conveying operation of each conveying device based on the conveying path of each conveying device, the phase difference of the conveying operation between the conveying devices, the line speed, and the processing speed.
- a press-to-transport phase difference ⁇ TP to be described later and a press-to-transport phase difference setting step (for example, step S11 in FIG. 3 to be described later).
- the conveyance path of the conveyance device is set so that the clearance between the conveyance device or the workpiece conveyed by the conveyance device and the lower mold is minimized. Therefore, the conveyance path can be set at a low position.
- the phase difference of the transport operation between the transport devices is set so that the clearance between the work unloaded from the press machine and the work loaded into the press machine is minimized after setting the processing speed of the press machine. Since it is set, it is possible to minimize the in-mold time in which the two conveying devices stay in one press at the same time.
- phase difference between the raising / lowering operation of each press and the conveying operation of each conveying device is as follows: conveying path of each conveying device set as described above, phase difference of conveying operation between each conveying device, line speed And based on the processing speed.
- the production cycle in this press line can be improved.
- the production cycle of the press line can be ascertained from the mold design stage, a production plan for the press line can be quickly established.
- the line speed and the processing speed are respectively set to maximum values in the line speed setting step and the processing speed setting step.
- the line speed and the processing speed are set to the maximum values, respectively, the transport path of the transport device, the phase difference of the transport operation between the transport devices, the lifting operation of each press machine, and the Sets the phase difference from the transfer operation.
- movement of a press machine and the conveyance operation of a conveying apparatus can be set so that the production cycle of the whole press line can be improved.
- phase difference between the raising / lowering operation of each press machine and the conveying operation of each conveyance device set in the phase difference setting process between the press conveyance can be set within the workable range.
- a work availability determination step (for example, step S9 in FIG. 3 described later), and in the work availability determination step, if it is determined that the phase difference cannot be set within the workable range, the line speed is increased.
- the phase difference setting step between the conveying devices, the phase difference setting step between the press conveyances, and the work availability determination step are executed again. In the work availability determination step, the phase difference is within the workable range. Is determined to be settable, the phase difference is set within the workable range.
- the phase difference between the raising / lowering operation of each press and the conveying operation of each conveying device is determined whether or not the phase difference between the raising / lowering operation of each press and the conveying operation of each conveying device can be set within the workable range, and it is determined that the phase difference cannot be set.
- the phase difference between the lifting operation of each press and the conveying operation of each conveying device is set within the workable range by reducing the line speed that was provisionally set to the maximum value in the previous process. Is done. Therefore, the phase difference between the raising / lowering operation and the conveying operation can be set within the workable range while minimizing the reduction of the line speed.
- the processing speed is set to a smaller value so that the clearance (for example, ⁇ U1 and ⁇ U2 described later) between the conveying device and the workpiece conveyed by the conveying device and the upper die is minimized. It is preferable to further include a processing speed optimization step (for example, steps S12, S13, and S14 in FIG. 3 described later).
- the processing speed of each press is held by the transport device and the transport device based on the transport path set as described above, the phase difference of the transport operation between the transport devices, and the line speed.
- the clearance between the workpiece and the upper die is set to be minimum. Therefore, the processing speed of each press can be set to a minimum without lowering the line speed, that is, the production cycle of the entire press line. Thereby, the electric power required for driving the press machine can be minimized. In addition, the load on the press machine and the impact load on the mold can be minimized.
- the operation condition setting method of the press line of the present invention only by determining the shape of the die of the transport device or the press machine, the optimum line speed, transport path, and transport operation of the transport device according to this shape, That is, since the conveying operation of the conveying device can be automatically set, the production cycle in this press line can be improved. Further, since the production cycle of the press line can be determined at the mold design stage, a production plan for the press line can be quickly established.
- FIG. 1 It is a figure which shows schematic structure of the press line to which the operating condition setting method which concerns on one Embodiment of this invention was applied. It is a block diagram which shows the structure of the conveyance motion calculating apparatus which concerns on the said embodiment. It is a flowchart which shows the procedure which produces
- FIG. 1 is a diagram showing a schematic configuration of a press line 1 to which an operation condition setting method according to an embodiment of the present invention is applied.
- the press line 1 includes a plurality of press machines 2 that process the workpiece W, a plurality of transport devices 3 that are provided along with the press machines 2 and transport the workpiece W between the press machines 2, and A control device 4 that controls the operation of the press machine 2 and the operation of each transport device 3 is provided.
- the press line 1 manufactures a product having a predetermined shape from a flat workpiece through a plurality of pressing processes by each pressing machine 2.
- the plurality of pressing machines 2 are arranged in the same order as the progress of the pressing process, and each pressing process 2 is assigned to each pressing process.
- the pressing process proceeds in order from the left side to the right side in FIG.
- the direction in which the pressing process proceeds and the transport direction Y in which each transport device transports the workpiece are the same.
- Each press machine 2 moves the upper die 22 closer to and away from the lower die 21, the lower die 21 arranged below the workpiece W, the upper die 22 arranged facing the lower die 21, and the lower die 21. It has an elevating mechanism 23 and a controller (not shown) that controls the elevating mechanism 23.
- the above press machine 2 presses the workpiece W by moving the upper die 22 up and down relative to the lower die 21.
- Each conveying device 3 includes a crossbar 32 to which a plurality of vacuum cups 31 are connected, a moving device (not shown) that moves the crossbar 32 along a conveying path C set between adjacent press machines, and this movement. And a controller (not shown) for controlling the apparatus.
- the conveyance path C of each conveyance device 3 includes a forward path CO that extends from a press machine 2 that executes a pre-press process to a press machine 2 that executes a next press process, and a press machine that executes the next press process. And a return path CB extending from 2 to the press 2 that executes the pre-pressing process.
- Each conveyance device 3 moves the cross bar 32 along the conveyance path C between the adjacent press machines 2, and the workpiece W processed by the press machine 2 corresponding to the previous press process is transferred to the next press. It conveys to the press machine 2 corresponding to a process. That is, the transfer device 3 moves on the forward path CO while holding the workpiece W, and runs idle without holding the workpiece W on the return path CB.
- Each conveyance device 3 operates as follows and conveys the workpiece W.
- the cross bar 32 is moved along the return path CB between the upper mold 22 and the lower mold 21 of the press machine 2 corresponding to the previous press process.
- the processed workpiece W is sucked by the vacuum cup 31 and is held.
- the cross bar 32 is moved along the forward path CO while holding the workpiece W between the upper mold 22 and the lower mold 21 of the press machine 2 corresponding to the next press process.
- the held work W is placed on the lower mold 21 of the press machine 2.
- the control device 4 transmits a control signal to the controllers of each press machine 2 and each transport device 3 based on predetermined press motion data and transport motion data, and periodically raises and lowers each press machine 2 (hereinafter, “ As well as a periodic transport operation (hereinafter referred to as “transport motion”) of each transport device 3.
- the transport motion calculation device 5 reads the press motion data that defines the press motion of each press machine 2, generates transport motion data that defines the transport motion of each transport device 3, and further generates the press motion data and the transport motion data. To the control device 4.
- the press motion data defining the press motion includes information about the press motion such as the speed, position, and time for driving the upper die 22 of each press machine 2.
- the speed at which the upper die 22 is driven is characterized as a processing speed indicating the processing capability of the workpiece of the press machine 2, that is, a press SPM. Accordingly, the larger the press SPM, the shorter the period for raising and lowering the upper die 22.
- the transport motion data defining the transport motion includes information regarding the transport path C of each transport apparatus 3 and the speed at which the transport apparatus 3 is driven along the transport path C.
- the conveyance path C of the conveyance device 3 is defined as a locus of the center position of the crossbar 32 in the three-dimensional space.
- the transfer motion data includes information on the line SPM as the line speed indicating the work production capacity, that is, the quantity that can be processed in one minute in the press line 1. That is, the production cycle in the press line 1 can be improved by setting this line SPM to a large value. Moreover, the speed and time which drive each conveying apparatus 3 are determined according to this line SPM.
- the transport motion data includes information on the phase difference of the transport motion between the transport apparatuses 3 (hereinafter referred to as “phase difference between transport apparatuses”). included.
- the transport motion data includes the transport motion of each press machine 2 and each transport device. 3 includes information regarding a phase difference between the three transport motions (hereinafter referred to as a “press-transport phase difference”).
- the transport motion calculation device 5 transmits press motion data and transport motion data including the above information to the control device 4.
- FIG. 2 is a block diagram illustrating a configuration of the transport motion calculation device 5.
- the transport motion calculation device 5 includes an input device 51, a storage device 52, and a calculation device 53.
- the input device 51 includes hardware such as a keyboard and a mouse that can be operated by an operator. Data and commands input by operating the input device 51 are input to the arithmetic device 53.
- the storage device 52 is configured by hardware such as a hard disk or a CDROM. Various data are stored in the storage device 52, and the stored data is appropriately input to the arithmetic device 53.
- the arithmetic unit 53 is configured by hardware such as a CPU, a ROM, and a RAM.
- the arithmetic device 53 includes a plurality of functional blocks realized by these hardware. More specifically, the arithmetic device 53 includes a calculation data reading unit 531, a calculation data processing unit 532, a conveyance path calculation unit 533, a conveyance path evaluation unit 534, and an inter-conveyer phase difference calculation unit 535.
- the workable range calculation unit 536, the workable range evaluation unit 537, and a motion data output unit 538 are included.
- the storage device 52 stores CAD data that defines the shapes of the upper and lower dies of each press, the shape of the workpiece in each process, and the position of the vacuum cup of each transport device. In addition to the CAD data, the storage device 52 stores preset press motion data.
- the calculation data reading unit 531 reads various CAD data stored in the storage device 52 (see step S1 in FIG. 3 described later).
- the calculation data processing unit 532 performs preprocessing on the CAD data read by the calculation data reading unit 531 to reduce the load on calculation (see step S2 in FIG. 3 described later).
- the transport path calculation unit 533 calculates the transport path C of each transport apparatus based on the preprocessed CAD data and various transport conditions including the line SPM (see step S4 in FIG. 3 described later). .
- the conveyance path evaluation unit 534 evaluates the conveyance path C calculated by the conveyance path calculation unit 533 and determines whether or not the workpiece can actually be conveyed along the conveyance device C (see FIG. 3 described later). (See step S5).
- the inter-conveyer phase difference calculation unit 535 calculates the inter-conveyer phase difference based on the transport path C calculated by the transport path calculation unit 533 and the line SPM input from the input device 51 (FIG. 3 described later). Step S7).
- the workable range calculation unit 536 reads the press motion data stored in the storage device 52. Further, when the press line is operated with the read press motion data and the set transport path C and the phase difference between the transport devices, the upper mold and the transport device and the work transported by the transport device interfere with each other. First, the workable range in which the press-conveyance phase difference can be set is calculated (see step S8 in FIG. 3 described later).
- the workable range evaluation unit 537 evaluates the calculated workable range and determines whether the workable range has been secured for all the presses. When the workable range can be secured, the press-conveyance phase difference is set within this range (see step S9 in FIG. 3 described later).
- the motion data output unit 538 transmits the press motion data and the transport motion data calculated as described above to the control device 4 (see step S16 in FIG. 3 described later).
- step S1 various CAD data are read.
- CAD data that defines the shapes of the lower and upper dies of each press, the shape of the workpiece in each pressing process, and the position of the vacuum cup of each transport device is read from the storage device.
- a conveyance condition is input.
- the conveyance conditions indicate various set values that are required when the workpiece is conveyed by the conveyance device.
- the conveyance conditions include the height of the crossbar when the workpiece is sucked, the lift amount and the feed amount with respect to the lower mold of the workpiece, and the workpiece when the workpiece is conveyed.
- a set value such as an amount related to the held posture is included.
- the line SPM is provisionally set to the maximum value. The line SPM set to the maximum value here is reset to an appropriate value in the steps S7 to S11 described in detail later.
- step S3 calculation data processing is performed.
- the CAD data read in step S1 is preprocessed to reduce the load on the calculation of the transport path C and the workable range described later.
- FIG. 4 is a schematic diagram illustrating a configuration of the transport path C and the crossbar 32 of the transport apparatus 3 that moves along the transport path C. As shown in FIG. 4, the transport path C is set so that the clearance ⁇ D1 or ⁇ D2 between the transport device 3 or the workpiece W transported by the transport device 3 and the lower mold 21 is minimized.
- the transport apparatus 3 runs idle without holding the workpiece W. For this reason, the return path CB is set so that the clearance D1 between the vacuum cup 31 and the lower mold 21 of the transport device 3 is minimized.
- the forward path CO of the transport path C the transport apparatus 3 moves while holding the workpiece W. Therefore, the forward path CO is set so that the clearance D2 between the workpiece W held by the transport device 3 and the lower mold 21 is minimized. In this way, by setting the transport path C so that the clearance with the lower mold 21 is minimized, it is possible to easily avoid interference between the upper mold 22 that moves up and down with respect to the lower mold 21 and the transport device 3. .
- step S5 it is determined whether or not the workpiece can be conveyed along the set conveyance path C.
- the crossbar 32 is moved along the transport path C, the work or the like along the transport path C is actually transported by calculating the load on the moving device that moves the crossbar 32. Determine if it is possible. If this determination is YES, the process proceeds to step S6, and if NO, the process proceeds to step S4 to reset the transport route C that can be transported.
- step S6 press motion data is read.
- the press SPM reads the maximum press motion data.
- the press SPM is set to the maximum value as the provisional value.
- the press SPM of each press is reset to an appropriate value in steps S12 to S14 described in detail later.
- FIG. 5 is a diagram showing a state in which two conveying devices 3A and 3B exist simultaneously in the mold of the press machine 2. As shown in FIG. More specifically, FIG. 5 shows a state in which after the workpiece WA is processed by the press machine 2, the workpiece WB before processing is carried in by the transfer device 3B while the processed workpiece WA is carried out by the transfer device 3A.
- FIG. 5 shows a state in which after the workpiece WA is processed by the press machine 2, the workpiece WB before processing is carried in by the transfer device 3B while the processed workpiece WA is carried out by the transfer device 3A.
- the time difference between the time when the processed workpiece WA is unloaded from the press machine 2 and the time when the unprocessed workpiece WB is loaded into the press machine 2 is as much as possible. It is preferable to shorten it. That is, it is preferable to reduce the time spent in the molds of the two transfer devices 3A and 3B as much as possible. Therefore, the phase difference between the transfer devices 3A and 3B is determined in the mold of the press machine 2 between the post-processed workpiece WA unloaded from the press machine 2 and the unprocessed work WB loaded into the press machine 2.
- the clearance ⁇ L along the transport direction Y is set to be minimum.
- step S8 the workable range is calculated.
- the workable range refers to the upper mold and the transfer device when the press line is operated under the set transfer path C, transfer device phase difference ⁇ TH, line SPM, and press SPM of each transfer device.
- a range in which the press-conveyance phase difference ⁇ TP can be set without interference with the workpiece held by the conveying device is shown.
- FIG. 6 is a view showing the trajectory of the cross bar 32 of the transport device 3 as viewed from the upper mold 22. More specifically, FIG. 6 shows the trajectory of the crossbar 32 that moves along the set conveyance path when the upper die 22 is moved up and down under a predetermined press-conveyance phase difference. It is the figure seen from 22 stationary systems.
- the work range is calculated by setting the range in which the press-conveyance phase difference ⁇ TP can be set without interference between the upper mold and the transport device or the work as a workable range.
- FIG. 7 is a diagram showing a workable range of the press-conveyance phase difference.
- the phase difference between the press and the conveyance includes an area where the upper mold and the conveyance device interfere with each other and an area where the conveyance cannot be carried out. Therefore, the workable range is limited to an area where unloading and loading are possible.
- a workable range in which the press-conveyance phase difference can be set as shown in FIG. 7 is calculated for each press.
- step S9 it is determined whether or not work is possible, that is, whether or not the workable range has been secured for all the presses in step S8. If this determination is YES, the process proceeds to step S11, and after setting the press-conveyance phase difference ⁇ TP at the approximate center of the workable range, the process proceeds to step S12. If this determination is NO, the process proceeds to step S10, the line SPM is set to a smaller value, and then the process proceeds to step S7. That is, the line SPM is reduced until a workable range is secured in all the press machines.
- step S ⁇ b> 12 it is determined whether or not there is a surplus in the workable range for each press calculated in step S ⁇ b> 8. If this determination is YES, that is, if there is a surplus in the workable range, the process proceeds to step S13, the press SPM in the press with surplus is set to a smaller value, and then the process proceeds to step S14. In step S14, the workable range is calculated again under the set press SPM, and the process proceeds to step S12. If this determination is NO, the setting of the press motion data and the transport motion data is terminated, and the process proceeds to step S15.
- FIG. 8 is a diagram illustrating a change in the workable range when the press SPM is reduced.
- FIG. 9 is a diagram illustrating a change in the trajectory of the crossbar 32 of the transport device 3 as viewed from the upper mold 22 when the press SPM is reduced.
- step S15 an animation that reproduces the press motion of the press and the transport motion of the transport device is generated based on the set press motion data and transport motion data. The operator looks at this animation and finally confirms the press motion data and the transport motion data.
- step S16 the press motion data and the transport motion data are transmitted to the control device, and this process is terminated.
- the clearances ⁇ D ⁇ b> 1 and ⁇ D ⁇ b> 2 between the lower mold 21 and the conveyance device 3 or a workpiece conveyed by the conveyance device 3 are set to a minimum after setting the line SPM. Therefore, interference with the upper mold 22 can be minimized.
- the inter-conveyer phase difference ⁇ TH is set so that the clearance ⁇ L between the work carried out from the press machine 2 and the work carried into the press machine is minimized after the press SPM of the press machine 2 is set. As a result, it is possible to minimize the in-mold time in which the two conveying devices stay in the single press 2 at the same time.
- the press-conveyance phase difference ⁇ TP between the press motion of each press machine 2 and the transport motion of each transport device 3 is the transport path of each transport device set as described above, and the transport between each transport device. It is set based on the phase difference of operation, line SPM, and press SPM.
- the production cycle in the press line 1 can be improved.
- the production cycle of the press line can be ascertained from the mold design stage, a production plan for the press line can be quickly established.
- the transport path C of the transport device 3 After setting the line SPM and the press SPM to the maximum values, the transport path C of the transport device 3, the phase difference of the transport motion between the transport devices 3, and the press motion of each press machine 2 and each transport device A phase difference ⁇ TP with respect to the transport motion No. 3 is set. Thereby, the press motion of the press machine 2 and the conveyance motion of the conveyance apparatus 3 can be set so that the production cycle of the whole press line can be improved.
- phase difference between the press motion of each press machine 2 and the transfer motion of each transfer device 3 can be set within the workable range, and it is determined that it cannot be set.
- the phase difference of the transport motion between the transport devices 3 again, and the phase difference ⁇ TP between the press motion of each press machine 2 and the transport motion of each transport device 3 are set.
- the phase difference ⁇ TP between the press motion of each press machine 2 and the transport motion of each transport device is within the workable range by reducing the line SPM that is temporarily set to the maximum value in the previous process.
- the press-conveyance phase difference ⁇ TP can be set within the workable range while minimizing the reduction of the line SPM.
- the press SPM of each press machine 2 was transported by the transport device 3 and the transport device 3 under the transport path C, the inter-transport device phase difference ⁇ TH, and the line SPM set as described above.
- the clearances ⁇ U1 and ⁇ U2 between the workpiece and the upper die 22 are set to be minimum. Therefore, the press SPM of each press machine 2 can be set to the minimum without lowering the line SPM, that is, the production cycle of the entire press line 1. Thereby, electric power required in order to drive the press machine 2 can be minimized.
- the load applied to the press machine 2 and the impact load applied to the molds 21 and 22 can be minimized.
- the present invention is not limited to the above-described embodiment, and modifications, improvements and the like within a scope that can achieve the object of the present invention are included in the present invention.
- the operation condition setting method of the press line 1 including the four steps, that is, the four press machines 2 has been described.
- the number of press machines included in the press line is not limited thereto.
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Abstract
Description
図1は、本発明の一実施形態に係る運転条件設定方法が適用されたプレスライン1の概略構成を示す図である。
先ず、前プレス工程に対応するプレス機2の上型22と下型21との間へ、クロスバー32を復路CBに沿って移動する。
次に、バキュームカップ31で加工後のワークWを吸引し、このワークWを保持する。
次に、次プレス工程に対応するプレス機2の上型22と下型21との間へ、ワークWを保持したまま、クロスバー32を往路COに沿って移動する。
次に、保持したワークWをプレス機2の下型21に設置する。
プレスモーションを規定するプレスモーションデータには、各プレス機2の上型22を駆動する速度、位置、および時刻等のプレスモーションに関する情報が含まれる。この上型22を駆動する速度は、プレス機2のワークの加工能力を示す加工速度、すなわち、プレスSPMとして特徴付けられる。したがって、このプレスSPMが大きいほど、上型22を昇降する周期が短くなる。
またさらに、周期的なプレスモーションを繰り返す各プレス機2と、周期的な搬送モーションを繰り返す各搬送装置3とを制御するため、搬送モーションデータには、各プレス機2の搬送モーションと各搬送装置3の搬送モーションとの間の位相差(以下、「プレス-搬送間位相差」という)に関する情報が含まれる。
搬送モーション演算装置5は、入力装置51と、記憶装置52と、演算装置53と、を含んで構成される。
記憶装置52は、ハードディスクやCDROMなどのハードウェアで構成される。この記憶装置52には、各種データが記憶されており、記憶されたデータは、演算装置53に適宜入力される。
計算用データ処理部532は、計算用データ読込部531により読み込まれたCADデータに前処理を施し計算にかかる負荷を軽減する(後述の図3のステップS2を参照)。
搬送経路評価部534は、搬送経路算出部533により算出された搬送経路Cを評価し、実際に搬送装置Cに沿ったワークの搬送が可能であるか否かを判別する(後述の図3のステップS5参照)。
モーションデータ出力部538は、以上のようにして算出されたプレスモーションデータおよび搬送モーションデータを、制御装置4に送信する(後述の図3のステップS16を参照)。
また、このステップにおいて、ラインSPMは暫定的に最大値に設定される。ここで最大値に設定されたラインSPMは、後に詳述するステップS7~S11の工程において、適切な値に再設定される。
図4は、搬送経路Cとこの搬送経路Cに沿って移動する搬送装置3のクロスバー32の構成を示す模式図である。
図4に示すように、搬送経路Cは、搬送装置3またはこの搬送装置3により搬送されるワークWと、下型21との間のクリアランスΔD1またはΔD2が最小になるように設定される。
搬送経路Cのうち往路COでは、搬送装置3はワークWを保持しながら移動する。このため、往路COは、搬送装置3により保持されたワークWと下型21との間のクリアランスD2が最小になるように設定される。
このように、下型21とのクリアランスが最小となるように、搬送経路Cを設定することにより、下型21に対し昇降する上型22と搬送装置3との干渉を避け易くすることができる。
図5は、プレス機2の型内に2つの搬送装置3A,3Bが同時に存在した状態を示す図である。より具体的には、図5は、プレス機2でワークWAを加工した後、この加工後のワークWAを搬送装置3Aで搬出しながら、加工前のワークWBを搬送装置3Bで搬入する状態を示す図である。
図7に示すように、プレス-搬送間位相差には、上型と搬送装置とが干渉し搬出できない領域と、搬入できない領域とが含まれる。そこで、作業可能範囲は、搬出および搬入が可能な領域に限られる。
このステップでは、各プレス機に対して、図7に示すような、プレス-搬送間位相差を設定可能な作業可能範囲を算出する。
この判別がYESの場合には、ステップS11に移り、作業可能範囲の略中心にプレス-搬送間位相差ΔTPを設定した後、ステップS12に移る。
この判別がNOの場合には、ステップS10に移り、ラインSPMをより小さな値に設定した後、ステップS7に移る。すなわち、全プレス機に作業可能範囲が確保されるまで、ラインSPMを低減する。
この判別がYESの場合、すなわち、作業可能範囲に余剰がある場合、ステップS13に移り、余剰があるプレス機におけるプレスSPMをより小さな値に設定した後、ステップS14に移る。ステップS14では、設定されたプレスSPMのもとで作業可能範囲を再び算出し、ステップS12に移る。
この判別がNOの場合には、プレスモーションデータ、および搬送モーションデータの設定を終了し、ステップS15に移る。
図9は、プレスSPMを低減した場合における上型22から視た搬送装置3のクロスバー32の軌跡の変化を示す図である。
したがって、ステップS12~S14では、設定された各搬送装置の搬送経路C、各搬送装置間位相差ΔTH、ラインSPM、およびプレス-搬送間位相差ΔTPのもとで、上型22とクロスバーの軌跡との間のクリアランスΔU1,ΔU2が最小になるまで、プレスSPMが低減される。
(1)搬送装置3の搬送経路Cは、ラインSPMを設定した上で、搬送装置3またはこの搬送装置3により搬送されるワークと、下型21との間のクリアランスΔD1,ΔD2が最小になるように設定されるため、上型22との干渉を最小限にすることができる。また、搬送装置間位相差ΔTHは、プレス機2のプレスSPMを設定した上で、プレス機2から搬出するワークとこのプレス機に搬入するワークとの間のクリアランスΔLが最小となるように設定されるため、2つの搬送装置が同時に1つのプレス機2内に滞在する型内時間を最小にすることができる。また、各プレス機2のプレスモーションと各搬送装置3の搬送モーションとの間のプレス-搬送間位相差ΔTPは、以上のように設定された各搬送装置の搬送経路、各搬送装置間の搬送動作の位相差、ラインSPM、およびプレスSPMに基づいて設定される。
上記実施形態では、4つの工程、すなわち、4台のプレス機2を備えるプレスライン1の運転条件設定方法について説明したが、プレスラインが備えるプレス機の数は、これに限るものではない。
2…プレス機
21…下型
22…上型
3…搬送装置
4…制御装置
5…搬送モーション演算装置
Claims (4)
- 下型に対し上型を昇降することでワークをプレス加工する複数のプレス機と、
これらプレス機の間で、所定の搬送経路に沿ってワークを搬送する複数の搬送装置と、
各プレス機の周期的な昇降動作、並びに、各搬送装置の搬送経路に沿った周期的な搬送動作を制御する制御装置と、を備えたプレスラインの運転条件設定方法であって、
前記プレスラインにおけるワークの生産能力を示すライン速度を設定するライン速度設定工程と、
前記搬送装置または当該搬送装置により搬送されるワークと、前記下型との間のクリアランスが最小になるように、前記搬送装置の搬送経路を設定する搬送経路設定工程と、
前記プレス機のワークの加工能力を示す加工速度を設定する加工速度設定工程と、
プレス機から搬出するワークと当該プレス機に搬入するワークとの間のクリアランスが最小になるように、各搬送装置間の搬送動作の位相差を設定する搬送装置間位相差設定工程と、
前記工程において設定された各搬送装置の搬送経路、各搬送装置間の搬送動作の位相差、ライン速度、および加工速度に基づいて、各プレス機の昇降動作と各搬送装置の搬送動作との間の位相差を設定するプレス搬送間位相差設定工程と、を含むことを特徴とするプレスラインの運転条件設定方法。 - 前記ライン速度設定工程および前記加工速度設定工程では、前記ライン速度および前記加工速度を、それぞれ最大値に設定することを特徴とする請求項1に記載のプレスラインの運転条件設定方法。
- 前記プレス搬送間位相差設定工程において設定された各プレス機の昇降動作と各搬送装置の搬送動作との間の位相差を、作業可能範囲内で設定可能であるか否かを判定する作業可否判定工程をさらに含み、
前記作業可否判定工程において、作業可能範囲内で位相差を設定可能でないと判定された場合には、ライン速度をより小さな値に設定するとともに、前記搬送装置間位相差設定工程、前記プレス搬送間位相差設定工程、および前記作業可否判定工程を再び実行し、
前記作業可否判定工程において、作業可能範囲内で位相差を設定可能であると判定された場合には、当該位相差を作業可能範囲内で設定することを特徴とする請求項2に記載のプレスラインの運転条件設定方法。 - 設定された各搬送装置の搬送経路、各搬送装置間の搬送動作の位相差、ライン速度、加工速度、および各プレス機の昇降動作と各搬送装置の搬送動作との間の位相差のもとで、搬送装置およびこの搬送装置に保持されたワークと前記上型との間のクリアランスが最小になるように、加工速度をより小さな値に設定する加工速度最適化工程をさらに含むことを特徴とする請求項3に記載のプレスラインの運転条件設定方法。
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