Patent Grant
8382084
The invention relates to a centering device for flat workpieces, in particular sheet-metal blanks to be processed in a press. The invention furthermore relates to a method for setting up a centering device.
Pre-blanked sheet-metal parts or “blanks” are often processed further in a press (e.g. a multi-station press or press line). Before actual processing takes place in the press, the blanks supplied must generally be unstacked or separated, washed and, if required, oiled. To allow the blanks to be processed further in a precise manner in the press, they must be precisely positioned and oriented in a predetermined alignment after the operations mentioned and before being introduced into the press.
Positioning and alignment are frequently performed with known centering stations, which have mechanical slides and stops against which the blank can be aligned. However, these have the disadvantage of requiring manual conversion when the type of blank is changed, a complex procedure involving repositioning and re-orienting the slides and stops. Moreover, when processing irregularly shaped sheets or a plurality of small sheets, a large number of slides and stops is required to ensure correct positioning.
Automatic solutions have been developed to counter the disadvantages mentioned, especially for cases where the type of blank to be processed in a press changes frequently.
EP 865 331 B1 (Reinhardt Maschinenbau GmbH), for example, describes a bending center and a method of presenting a sheet-metal part to a bending cell of the bending center. After the position of the sheet-metal part has been determined by means of a sensor, it is positioned exactly in one direction by means of a manipulator as it is introduced into the bending cell. Provision is made for the sensor to be moved in two different directions to enable the position of the sheet-metal part to be determined in both directions and its angular misalignment to be determined with the minimum number of sensors. It is also described as advantageous to attach the sensor to the manipulator arrangement in order to exploit the mobility of the latter. In addition to a manipulator that can be moved in a first direction, this document describes a second manipulator, which can operate simultaneously with the first manipulator and can be moved in a second direction. The sensor for determining the position of the sheet-metal part is embodied, inter alia, as a light barrier, arranged in a fork, for detecting the edges of the sheet-metal part.
However, the overall length of this arrangement is large because the manipulators are arranged in series. Moreover, it is limited to the simultaneous positioning of one sheet-metal part in each case.
U.S. Pat. No. 5,293,984 (Bobst S. A.) describes a device for preparing and aligning bundled flat workpieces. It describes a transport device comprising sets of several driven rollers. A table with moving balls can be moved upwards, downwards and sideways between the rollers.
This device is of very complex construction and, once again, is limited to the simultaneous positioning of individual workpieces.
W. Strothmann GmbH, Schloss Holte-Stukenbrock (Germany) offers a loading feeder with an integrated image recognition and processing system, which matches the position of the blank to the specified values as it is transferred into the press. The system is based on whiplash loading feeders, which can not only traverse along the conventional axes but can also perform rotary movements about the u axis, allowing precise control of the angular alignment of the sheets. The actual optical centering system comprises a camera and the image recognition and processing platform, which is linked to the CNC control system of the feeder. While the blank is being transported on the conveyor belt upstream of the press, the optical system detects its position, enabling the loading feeder to pick up the component in an appropriate manner. To specify a new target position, a workpiece must be placed correctly in the press just once, then removed by the feeder and deposited under the camera for detection without a change in position.
However, this solution requires the use of a specific loading feeder of complex construction, which must furthermore be matched to the press. For example, the travel geometry of the loading feeder must be such that the workpieces to be processed can be transported to the target position in the press through an appropriate press aperture. Moreover, a single loading feeder can perform just one position and/or angle correction during loading; if the requirement is to change the position and/or orientation of a plurality of workpieces independently of one another, a plurality of loading feeders is needed.
It is the object of the invention to provide a centering device belonging to the technical sphere mentioned at the outset which is of simple construction and can re-orient a plurality of workpieces simultaneously.
The solution to the object is defined by the features of claim 1. According to the invention, the centering device comprises
If both tables are rotated jointly about the third vertical axis, the tables form a common supporting surface. In this operating mode, the tables are stationary relative to one another during rotation and the supporting surface is thus rotated as a whole. In the other operating mode, the tables are rotated individually about spaced vertical axes of rotation; the tables and their supporting surfaces thus move relative to one another.
With the device according to the invention, it is thus possible, without conversion work, to correctly orient either an individual workpiece, which can take up the entire width of the centering device, or two narrower workpieces at the same time for subsequent processing. The axes of rotation make it possible to correct the angular position of the workpieces in such a way that they can be picked up, by a loading feeder of simple construction for example, and transferred to the next processing station. The invention is not limited to devices with precisely two tables but can be generalized to cover embodiments with three or more tables.
The centering device according to the invention advantageously comprises a control system which can be switched between a first operating mode and a second operating mode. In the first operating mode, orientation of large workpieces supported by both tables is performed by rotating both tables about the third axis, and, in the second operating mode, two relatively small workpieces, each supported by one of the tables, are oriented simultaneously by a procedure in which angular positioning of the two workpieces is performed independently by rotating the tables about the first and the second axes respectively. It is thus possible to change between the two operating modes by a simple switching process. Manual conversion work is unnecessary.
The rotation mechanism is preferably formed by a support which is mounted on a machine frame in such a way that it can be rotated about the third vertical axis and which supports both the first table and the second table. This allows simple construction and simple control of the device; in the first operating mode (rotation of both tables), the support is rotated about the third vertical axis together with both tables, while the tables are not moved relative to the support; in the second operating mode (individual rotary movements), the support stands still while the tables are rotated relative to the support.
As an alternative, the tables are mounted to allow movement relative to a plurality of axes in such a way that they can perform a mutually synchronous movement about the third vertical axis by superposition of movements relative to these axes, even when there is no physical axis of rotation at the location of the third axis. Such kinematics can be implemented, for example, by means of two mutually perpendicular horizontal linear axes and a vertical axis of rotation, it being unnecessary that the axis of rotation should coincide with the third vertical axis.
The first table and the second table advantageously comprise a device for linear movement of the workpieces in a direction transverse to a feed direction. This allows individual corrections to the position of the workpieces in a transverse direction.
For this purpose, the first table and the second table are advantageously mounted on the rotation mechanism in such a way that they can be moved transversely. The tables can thus be moved independently of one another in a transverse direction relative to the rotation mechanism.
If a single workpiece which takes up the supporting surfaces of both tables needs to be positioned in a transverse direction, the abovementioned devices for linear movement of the workpieces in a transverse direction can be moved synchronously with one another, or there is an additional device by means of which both tables are moved simultaneously, e.g. a device which acts on the rotation mechanism, in particular on the abovementioned support on which both tables are mounted.
Depending on the requirements of the downstream processing unit or of a loading feeder, centering devices which do not perform any corrections of the transverse position and thus do not require a device for linear movement of the workpieces in a transverse direction are also conceivable.
The first table and the second table preferably comprise a device for linear movement of the workpieces in a feed direction (longitudinal direction). This enables the workpieces to be positioned correctly in the feed direction as well. The loading feeder or some other transfer element can thus always take over the workpiece at the correct longitudinal position, allowing very simple construction and control of the feeder or element. It is particularly advantageous if the device according to the invention comprises both a device for linear movement of the workpieces in a transverse direction and a device for linear movement of the workpieces in a longitudinal direction. This is because in this case a workpiece can be placed ready on the support level in a precisely defined position and orientation, and the loading feeder or the transfer element can take over all the workpieces at this precisely defined position and transport them to the subsequent processing station, in the simplest case while retaining their orientation.
The device for linear movement of the workpieces in the feed direction is preferably formed by magnetic belts. This makes it possible to transport metallic workpieces, e.g. sheets to be formed, reliably and at high speed. The belts furthermore enable the workpieces to be picked up in a simple manner from an upstream transport device and allow transport movements beyond the actual supporting surfaces of the tables. As an alternative, it is possible to use devices of different construction, e.g. conventional conveyor belts or conveyor slats, on which the workpieces are held by friction or by positive engagement.
The two tables advantageously have spaced supporting elements, each arranged on one side in mutually opposite sections, which are arranged in such a way that they mesh in a region between the two tables and thereby form a supporting surface between the tables. This supporting surface, the support level of which coincides with the support levels of the two tables, prevents large workpieces supported by both tables from buckling or sagging and at the same time allows unhindered relative movements (rotations and/or linear movements) between the two tables. The supporting elements are, for example, of elongate design and extend alternately in a transverse direction from the first and from the second table. Their length and breadth are chosen in such a way that they do not collide with one another or with the opposite table even when the tables are closest together and the relative angle of rotation is at its maximum. It is particularly advantageous if the supporting elements have freely rotatable rollers or balls or a surface with an anti-friction coating to ensure that they pose the minimum possible resistance to movements of the workpieces on the supporting surface.
As an alternative, a supporting surface between the tables can be formed by elements of some other kind, e.g. by elements which are connected firmly to a base of the device or to an element arranged under the tables. If the only workpieces being processed in a plant are those with a certain minimum rigidity, a supporting surface between the tables may be completely unnecessary.
The centering device according to the invention preferably comprises a detection device for detecting a position and an orientation of a workpiece supplied. The position and orientation of the workpiece can then be corrected by the centering device on the basis of this acquired information.
The detection device is advantageously formed by a line scanner, which is arranged ahead of the first and the second tables in the feed path of the workpieces and extends in a transverse direction across a feed track for the workpieces. The position and orientation of the workpieces are thus detected by the line scanner while they are being fed in. The line scanner can be of simple construction, allows precise detection of position and orientation and, in contrast to other detection devices, e.g. video cameras, does not require complex image processing.
The centering device advantageously comprises a control device which is designed and programmed in such a way that it can use a light/dark profile of the workpiece detected by the line scanner to determine the position correction and angle correction to be performed by means of the rotatable tables. Recording a light/dark profile which reproduces the outer and, where applicable, inner contours of the workpiece provides data that can be processed easily and which allow precise positioning and orientation of the workpiece. In particular, the profile detected can be compared with the desired profile which represents the position and orientation expected by the downstream processing station or downstream loading feeder. Deviations between the light/dark profile and the desired profile are evaluated by the control system in a manner known per se and converted into corrections to be performed, e.g. corrections in the angle of rotation and in the longitudinal and transverse directions. The corrections are then implemented by the rotatable tables and the devices for transverse and longitudinal motion, ensuring that the workpiece corresponds to the desired profile in its final position and orientation.
The desired profile of a workpiece is generated in the context of setting up the centering device, preferably as follows:
Depending on configuration, the transport devices mentioned can also include the loading feeder; the decisive point is that all the devices involved that have a predetermined effect on the position and/or orientation of the workpiece during transport between the detection device and the processing station should be operated in reverse. The centering table is advantageously passive during set-up, i.e. does not perform any rotations or linear movements. In principle, however, the centering table can perform predetermined movements; these must then merely be taken into account in the calculation of the desired profile, in equalizing the desired profile and the detected profile, and/or in the calculation of the corrections to be carried out.
Further advantageous embodiments and combinations of features of the invention will emerge from the following detailed description and from the patent claims, taken in their entirety.
In the drawings used to explain the exemplary embodiment,
In all cases, identical parts are provided with identical references in the figures.
Working from the bottom upwards, the centering device 1 comprises a plurality of levels, situated one above the other (see, for example,
To enable the frame 40, which is constructed from steel I-section profiles, to be moved along the rails 20, respective roller guides 41, the rollers of which can roll on the corresponding rail 20, are arranged on each of its transverse profiles, in the region of its corners. The roller guides 41 and the rails 20 thus form a linear guide for the frame 40. Attached to the underside of the frame 40 there is furthermore an electric drive motor 42, which is coupled to two of the roller guides 41 by a transmission 43 and a shaft 44 (see
The support 60 is connected to the frame 40, on the one hand, by the vertically oriented axis 50 which passes both through the geometrical center of the support 60 and through that of the frame 40, the axis 50 permitting a relative rotation between the support 60 and the frame 40. Pitching movements of the support 60 relative to the frame 40 are prevented by respective pairs of roller guides 51, 52, which are situated opposite one another and are spaced apart from the axis 50 on both sides in the transverse and in the longitudinal direction. They comprise pairs of rollers, each attached to the frame 40, the axes of rotation of the rollers being horizontal and pointing towards the axis 50, and a rail guided between the rollers and attached to the support 60. Opposite rollers of the roller guides 51, 52 are set in such a way relative to one another that the rails are guided essentially without play in a vertical direction. Moreover, the roller guides 51, 52 are dimensioned in such a way that there is a certain play between the rails and the boundaries of the roller support in a horizontal plane, this play allowing unhindered rotation of the support 60 about the axis 50 by the required amount (a maximum of about 5° to position workpieces in the case of common applications).
To bring about the rotary motion between the frame 40 and the support 60, an electric drive motor 45 is attached to the top side of the frame 40, this drive motor likewise being controlled and supplied with current by means of the drag chain 21 mentioned. The drive motor 45 acts on a pinion 46, which interacts with an externally toothed gear segment 61 arranged in a fixed manner on the support 60 (see
A set of four roller guides 62 is arranged on both sides of the support 60, on the outer sides in the feed direction. As is clearly visible in
The two carriages 80.1, 80.2 are of essentially identical construction and have the same functionality. Unless otherwise stated, the following details relating to the carriages 80.1, 80.2 and elements mounted on them thus apply equally to both carriages 80.1, 80.2.
The support 100 is connected to the carriage 80, on the one hand, by the vertically oriented axis 90 which passes both through the geometrical center of the table 100 and through that of the carriage 80, the axis 90 permitting a relative rotation between the table 100 and the carriage 80. Pitching movements of the table 100 relative to the carriage 80 are prevented by respective pairs of roller guides 91, 92, which are situated opposite one another and are spaced apart from the axis 90 on both sides in the transverse and in the longitudinal direction. They comprise pairs of rollers, each attached to the carriage 80, the axes of rotation of the rollers being horizontal and pointing towards the axis 90, and a rail guided between the rollers and attached to the table 100. Opposite rollers of the roller guides 91, 92 are set in such a way relative to one another that the rails are guided essentially without play in a vertical direction. Moreover, the guides 91, 92 are dimensioned in such a way that there is a certain play between the rails and the boundaries of the roller support in a horizontal plane, this play allowing unhindered rotation of the table 100 about the axis 90 by the required amount (a maximum of about 5° in the case of common applications).
To bring about the rotary motion, an electric drive motor 85 is attached in the region of a corner of the carriage 80 that is on the outside in a transverse direction, this drive motor acting on a pinion 86, which, for its part, interacts with an internally toothed gear segment 101 arranged in a fixed manner in the corresponding corner region of the table 100 (see
Three magnetic belts 120 known per se, which revolve in a longitudinal direction, are arranged on the upper side of the table 100. They are driven jointly by a shaft 121, around which the magnetic belts run at one of their ends. The shaft 121 is driven via a transmission 102 by an electric drive motor 103, which is arranged on the table 100. With the aid of the magnetic belts 120, a workpiece fed in from the feed direction on the support level can be received by the table 100 and positioned in a longitudinal direction. Rows of freely rotatable rollers 122, each parallel to the magnetic belts 120, are arranged between adjacent magnetic belts 120 and to the outside of the magnetic belt 120 which is outermost in a transverse direction, the rollers 122 being arranged in such a way that, together with the magnetic belts 120, they form a continuous supporting surface. The rollers 122 prevent large-area workpieces of low rigidity from sagging; however, owing to their low rolling resistance, they allow unhindered longitudinal transport of the workpiece on the table 100.
As can be seen most clearly from
After the centering operation, which is described in detail below in conjunction with
In the situation illustrated in
As the first workpiece H1 is being centered, the second workpiece H2 is transported through the washing unit C and the oiling device D and onto the conveyor table E, where it is transported onwards in the feed direction by means of magnetic belts. This results in the situation illustrated in
As the operation continues, the first workpiece H1 is picked up from the centering device 1 by the loading device and fed to the first processing station. As soon as the workpiece H1 has been picked up, the centering device 1 returns to its starting position, in which the frame 40 is in its center position and in which the longitudinal direction of the frame is aligned parallel to the feed direction. The second workpiece H2 is then moved through the line scanner 200. During this process, the workpiece H2 passes through an incident-light unit, which comprises an elongate light source or a series of light sources arranged on one side of the transport track, and a corresponding elongate detection unit (camera) arranged on the same side of the transport track. Because the workpiece H2 only partially reflects the light emitted by the light source as it passes through the line scanner 200, the detection unit can thus be used to record a light/dark profile of the workpiece line by line. Once the workpiece has passed through the line scanner 200, there is a complete image of the inner and outer contours of the workpiece H2 available in a control system (not shown).
This image is then compared with a predetermined desired profile in the control system. The corrections to be carried out are determined from this comparison. These include a linear movement in a transverse direction, a linear movement in a longitudinal direction and a rotation about a vertical axis.
The workpiece H2 is then transported onwards by means of the magnetic belts of the conveyor table E and the centering device 1 until it is completely on the centering device 1, which is still in the starting position. The workpiece H2 is then centered in a manner dependent on the corrections which have been determined. This operation proceeds in the manner described above for workpiece H1. The process is continued by placing another workpiece on the supply table A, giving rise once more to the situation illustrated in
Where relatively small workpieces whose extent in the transverse direction is less than half that of the press are being processed, two workpieces at a time can be processed with the device according to the invention. For this purpose, these workpieces are deposited side by side on the supply table A and are moved through the washing unit C, the oiling device D and the line scanner 200 in parallel. The line scanner detects two light/dark profiles and matches these individually to two desired profiles. Two sets of correction values (transverse and longitudinal positioning, angle correction) are thus obtained. The two workpieces then pass to the two tables of the centering device 1.
To perform the corrections, the centering device is operated in a different operating mode, in which the axis of rotation 50 between the frame 40 and the support 60 is held stationary and in which the coupling of the transverse movements of the carriages 80.1, 80.2 within the control system is dispensed with. Instead, the axes of rotation 90 between the carriages 80.1, 80.2 and the tables 100.1, 100.2 are used, and the linear axes between the support 60 and the carriages 80.1, 80.2 are operated independently of one another (see
The desired profile, which specifies the position and orientation of the workpiece on the supporting surface of the centering device 1 can be generated as follows: first of all, the workpiece is placed in the first press station F in the correct orientation (see
Next, the workpiece is moved backwards through the line scanner 200 with the aid of the magnetic belts of the centering device 1 and of the conveyor table E, the travel counter to the feed direction being detected in this process. Otherwise, the centering device 1 remains passive, i.e. does not perform any transport movements in a transverse direction or any rotary movements. In the line scanner 200, the profile of the workpiece is detected. This then directly forms the desired profile, which is used to determine the correction values. In addition to the actual desired profile, the abovementioned travel is also included in the calculation; the corresponding value is thus communicated to the control system of the centering device 1 together with the desired profile.
The invention is not limited to the exemplary embodiment illustrated. In particular, it can also be generalized to include facilities with more than two parallel tables. For this purpose, the lower levels can be of identical construction to those in the example illustrated, while more than two carriages with the corresponding higher levels are arranged on the support.
Moreover, the two operating modes can be implemented differently. Instead of immobilizing some of the axes in each case, depending on the operating mode, it is possible to employ further axes in both operating modes in addition to the device for longitudinal transport. Thus, for example, it is also possible in the operating mode in which a plurality of workpieces are positioned in parallel, to employ those axes which rotate both tables jointly about a central vertical axis, or another dynamic axis is provided by means of which both carriages can be moved jointly in a transverse direction, e.g. by designing the linear axis between the floor-mounted rails and the frame as a dynamic axis. This is advantageous especially when a certain proportion of the necessary correction movements coincide for both workpieces and when particularly high dynamism is required. Positioning can thus be optimized by employing the additional axes.
Furthermore, it should be noted that it is not essential that all the rotational and linear axes described should be implemented and that their sequence, arrangement and/or orientation may differ from the embodiment shown. The design of the detection unit may also be different; thus, for example, a transmitted-light unit may be employed instead of an incident-light unit.
In summary, it may be stated that the invention provides a centering device which is of simple construction and can re-orient a number of workpieces simultaneously.
| Number | Date | Country | Kind |
|---|---|---|---|
| 07405136 | May 2007 | EP | regional |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/CH2008/000070 | 2/19/2008 | WO | 00 | 4/19/2010 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2008/134904 | 11/13/2008 | WO | A |
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| Number | Date | Country | |
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| 20100225035 A1 | Sep 2010 | US |
