Patent Application
20130319194
This application claims priority under 35 U.S.C. §119 to EP application serial number 12 169 979.7 filed on May 30, 2012. The contents of this priority application are hereby incorporated by reference in their entirety.
This disclosure relates to machine tools and related methods for moving a workpiece part away from a processing region of a machine tool.
Upon cutting a workpiece part free from a workpiece during processing of the workpiece (e.g., punching the workpiece), the workpiece part often times needs to be removed from the processing region of a machine tool used to process the workpiece or from a support plane that supports the workpiece. Accordingly, the workpiece part may be moved along the support plane on a workpiece table, for example, so that the workpiece part can be tipped over the edge of the workpiece table. In some examples, the workpiece part may be positioned over a parts chute that extends from the workpiece table so that the workpiece part can be discharged through the parts chute.
In some examples, a machine tool includes a hold-down device for holding the workpiece down against the support plane as the workpiece is being punched through. A stripper (e.g., a plate-shaped stripper) may be mounted to an end of the hold-down device. During the punching stroke (e.g., as the punch or a punching cutter punches through the workpiece), the stripper rests on an upper surface of the workpiece in order to hold the workpiece down against the workpiece support during the punching operation.
The hold-down device and/or the stripper can be used to discharge a workpiece part. In some examples, a punching tool includes a stepped hold-down device including an underside with first and second surfaces that do not lie in a common plane. The first surface clamps a portion severed from a remaining sheet, while the remaining sheet is unrestrained adjacent the second surface. To remove the severed sheet portion from the punching machine, the unrestrained remaining sheet can be displaced while the severed, clamped sheet portion is held securely or moved independently of the remaining sheet.
Alternatively, a workpiece part can also be discharged by moving the remaining workpiece along the support plane while the workpiece part that has been cut free is driven along the support plane and thereby pushed away from the processing region by the remaining workpiece.
The present disclosure relates to machine tools and methods for increasing a process reliability of moving workpiece parts away from processing regions of machine tools.
According to one aspect of the invention, a machine tool for processing plate-like workpieces by punching includes a punching tool including a punch and a punching die, a drive unit for moving the punch and the punching die relative to each other along a stroke axis for cutting a workpiece part free from a plate-like workpiece, a hold-down device that is movable along the stroke axis and that includes a stripper that rests on an upper surface of the plate-like workpiece while the plate-like workpiece is punched through by the punch, a detection device for detecting a reference position of the hold-down device along the stroke axis, wherein the stripper rests on the upper surface of the workpiece at the reference position, and a numerical control unit for positioning the stripper at a particular distance from the reference position such that a workpiece part that has been cut off from the workpiece during the punching process can be moved away from a processing region of the machine tool. To position the stripper at a desired distance above the workpiece, the method includes determining the position of the stripper or hold-down device at which the stripper contacts the upper surface of the workpiece and, starting from that position, selecting the distance, which is typically not greater than the thickness of the plate-like workpiece, so that the stripper is able to act as a guide and, at the same time, the workpiece part that has been cut free is prevented from being pushed over the remaining workpiece and becoming jammed between the stripper and the remaining workpiece.
In some embodiments, the machine tool includes a driver arrangement for coupling motion between the hold-down device and the punch while the stripper is lifted from the upper surface of the workpiece. Due to the motion coupling, the position of the hold-down device relative to the punch remains constant while the stripper is lifted from the upper surface of the workpiece and during a subsequent portion of the punching stroke. In this manner, the numerical control unit for positioning the stripper at the particular distance from the workpiece uses the drive unit of the punch for positioning the stripper at the particular distance from the upper surface of the workpiece. In certain embodiments, for example, where the hold-down device has its own drive unit (e.g., its own hydraulic drive unit), the numerical control unit for positioning the stripper can actuate the drive unit of the hold-down device.
In some embodiments, the numerical control unit is configured to recognize that motion coupling has begun by comparing the positions of the hold-down device and the punch along the stroke axis. Such motion coupling or synchronous movement of the punch and the hold-down device typically occurs only upon lifting the hold-down device from the upper surface of the workpiece. More specifically, the position of the hold-down device and/or stripper does not change when the workpiece is being punched through, whereas the position of the punch along the stroke axis does vary while the workpiece is being punched through. Accordingly, synchronous movement of the punch and the hold-down device only occurs during lifting of the hold-down device after withdrawal of the punch or punch cutter from the workpiece. Once the synchronous upward movement of the hold-down device and the punch begins, the punch (and accordingly, the hold-down device) may be stopped after traveling a particular distance above the upper surface of the workpiece (i.e., thereby forming a push-out position).
In certain embodiments, the detection device includes a measurement device for determining the position of the hold-down device along the stroke axis. The measurement device may be a displacement measurement device that includes an optical sensor for detecting the position of the hold-down device along the stroke axis. For displacement measurement, a scale may be provided on the hold-down device. In some examples, the scale includes equidistant position marks that can be sensed by the optical sensor. In some embodiments, a machine tool may include displacement measurement devices that operate based on other measurement principles (e.g., the principle of magnetostriction). In such an embodiment, a waveguide made of a ferromagnetic material is typically used as the measurement element, and a movable permanent magnet serves as a position indicator (e.g., as described in detail in an article entitled “Magnetostriktion” available at www.mtssensors.de).
In some examples, it is not imperative to determine the absolute position of the hold-down device relative to the fixed frame of the machine tool. Rather, it may be sufficient to recognize whether synchronous movement of the hold-down device and the punch or of a ram acting thereon is occurring, or whether the hold-down device and the punch are being moved independently of each other. A suitable measurement device for determining the displacement or position of the punch along the stroke axis is typically associated with the punch.
In certain embodiments, the hold-down device is connected to the punch via a pre-tensioning device, which, when in a resting position, positions a lower edge of the punch in a flush alignment with a lower edge of the stripper. In such a case, the hold-down device is typically spring-mounted on the punch such that the hold-down device and the punch are moved synchronously and in a motion-coupled manner along the stroke axis provided that the pre-tensioning device (e.g., a spring) remains at the resting position. Movement of the pre-tensioning device out of its resting position typically takes place if the underside of the stripper rests on the upper side of the workpiece during the punching stroke, since the workpiece forms an abutment, thereby causing the force exerted on the punch or the pre-tensioning device to increase and the pre-tensioning device to be compressed.
In some embodiments, the detection device is configured to detect the reference position of the hold-down device via a force exerted by the punch on a drive unit of the punching tool when the punch contacts the upper surface of the workpiece. The punching force increases once the punch reaches the upper surface of the workpiece. Accordingly, the increased force exerted on the drive unit (e.g. the ram) can be detected, for example, as described in EP1281455B1, which is herein incorporated by reference in its entirety. Since the lower edge of the stripper and the lower edge of the punch are flush, the position at which the lower edge of the punch contacts the upper side of the workpiece corresponds to the reference position of the stripper.
In certain embodiments, the control device is configured to specify the distance of the stripper from the upper surface of the workpiece based on a thickness of the workpiece to be processed. For reliable movement of the workpiece part away from the processing region, the distance of the stripper from the upper surface of the workpiece should be sufficiently small in order to prevent the workpiece part that is being pushed away from jamming between the remaining workpiece and the stripper. The numerical control unit may obtain the thickness of the processed workpiece from a storage device. In alternative embodiments, the thickness of the workpiece can be measured as a punching stroke is being performed, for example, as described in EP1281455B1, which is incorporated herein in its entirety by reference. A positioning of the stripper at a distance of half of the thickness of the workpiece has been found particularly advantageous for pushing workpiece parts away from the processing region. While the stripper may also be positioned at a different distance (e.g., a distance dependent on the workpiece thickness), selecting a distance greater than the thickness of the workpiece should generally be avoided. In some examples, the distance is between about 0*d and about 1.0*d. In some examples, the distance may also be specified independently of the thickness of the workpiece, for example, when the distance is so small (e.g. about equal to or less than 0.2 mm) that it is smaller than the workpiece thickness irrespective of the type of workpiece to be processed.
In some embodiments, the machine tool additionally includes a movement device for moving the workpiece part that has been cut free away from the processing region, by moving the workpiece part together with the workpiece along a support plane. In certain embodiments, a device that serves to move the workpiece along the support plane and that is provided on the machine tool can be used as a movement device. For example, the movement device may be a coordinate guide including a linear drive with which the tool, clamped in a collet chuck, may be moved or displaced over the support plane of a workpiece table.
In some embodiments, the detection device for detecting the reference position has a sensor mounted on the stripper. In some embodiments, the sensor is an optical sensor, which, when the stripper contacts the workpiece, is covered by the workpiece and therefore detects no radiation. When the stripper contacts the workpiece or is lifted off of the workpiece, then the radiation output detected by the optical sensor distinctly changes, so that the reference position of the stripper can be detected. Typically, the stripper is an electrically conductive component (e.g., a metal), and the workpiece (e.g., a metal sheet) is also an electrically conductive component. Therefore, the reference position may also be determined by a resistance measurement or a voltage measurement since lifting the stripper from the workpiece interrupts the electrical contact between the two components.
In another aspect of the invention, a method of moving a workpiece part away from a processing region of a machine tool for processing plate-like workpieces by punching includes moving a punch and a punching die relative to each other along a stroke axis for cutting the workpiece part free from a workpiece, wherein, while the workpiece is being punched through with the punch, a stripper mounted on a hold-down device of the machine tool rests on an upper surface of the workpiece, determining a reference position of the hold-down device along the stroke axis, at which the stripper contacts the upper surface of the workpiece, positioning the stripper at a particular distance from the reference position, and moving the workpiece part that has been cut free away from the processing region of the machine tool.
The workpiece part that has been cut free is typically pushed away from the processing region by the remaining workpiece along a support plane. Accordingly, the workpiece part may be moved to a discharge position of the machine tool. Example discharge positions include a location of a parts chute, an edge of the workpiece support or, a location of a parts slide. From the discharge position, the workpiece part can be transported away from the machine tool manually or by using suitable transport devices.
In some embodiments, the distance between the stripper and the upper surface of the workpiece depends on a thickness of the workpiece. The distance between the lower edge of the stripper and the upper surface of the workpiece should not be greater than the thickness of the workpiece.
In some embodiments, selecting the distance as at least half of the thickness of the workpiece ensures (e.g., especially in the case of thin workpieces having a thickness of less than 1 mm) that the workpiece part does not become jammed between the stripper and the die when being pushed away from the processing region. In certain embodiments, the distance may be selected as at least one quarter or at least one third of the thickness of the workpiece. In general, the distance should be greater than zero in order to prevent jamming.
In some embodiments, the hold-down device and the punch are motion-coupled during lifting of the stripper from the upper surface of the workpiece. When punching through the workpiece, the punch is moved along the stroke axis relative to the stripper, which rests on the workpiece in a fixed location. Upon lifting the stripper off of the workpiece, (i.e., after the punch or punching cutter has been withdrawn out of the workpiece), the hold-down device and the punch are motion-coupled via a driving arrangement (e.g., a mechanical driving arrangement).
In certain embodiments, detection that the motion coupling has begun occurs via a comparison of the positions of the hold-down device and the punch along the stroke axis. When the coupled motion begins, the positions of the hold-down device and the punch change synchronously (i.e., the spacing between the two positions remains constant) and can be detected by a suitable position measurement or displacement measurement device for the hold-down device and the punch.
In some embodiments, the hold-down device is connected to the punch via a pre-tensioning device that positions a lower edge of the punch in a flush alignment with a lower edge of the stripper when the pre-tensioning device is in a resting position. The reference position of the hold-down device is detected via a force exerted on a drive unit of the punching tool upon the punch contacting the upper side of the workpiece. Upon contact between the punch or stripper and the workpiece, the pre-tensioning device is displaced. As a result of such displacement, the force exerted on the drive unit or ram increases, thereby allowing the position at which the stripper and the lower edge of the punch rest on the upper surface of the workpiece to be detected. The desired distance can be set after the workpiece has been punched through, by moving the punch upwards from the reference position by a suitable value (e.g., half of the thickness of the metal sheet) so that the workpiece part can be reliably pushed away from the processing region.
A number of embodiments have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. For example, the features described above and the features set forth hereinafter may also be used individually or in any desired combination. The embodiments shown and described are not to be understood as forming a definitive list, but rather are of the nature of examples for illustrating the invention. Further advantages will be apparent from the description, the drawings, and the claims.
a-2d illustrate a method of performing a punching stroke with a punch, a hold-down device, and a stripper.
a-3e illustrate a method of performing a punching stroke in which a hold-down device is connected to a punch via a spring.
The punching/forming machine 1 further includes a punch holder 8 and a punch 9 that is supported by the punch holder 8. The punch holder 8 and the punch 9 are located near a front end of the upper arm of the machine frame 2. The punching/forming machine 1 further includes a die holder 10 and a punching die 11 that is supported by the die holder 10. The die holder 10 and the punching die 11 are located near a front end of the lower arm of the machine frame 2. The punch 9 and the punching die 11 together form a tool 12 for processing (e.g., severing) the metal sheet 4.
The punching/forming machine 1 includes a punch drive 13 and a die drive 14 (e.g., linear drives) that form a drive unit. The punch drive 13 is operable to raise and lower the punch holder 8 (and accordingly, the punch 9 supported thereon and secured thereto) relative to the workpiece table 3 along a stroke axis 15. Similarly, the die drive 14 is operable to raise and lower the die holder 10 (and accordingly, the punching die 11 supported therein and secured thereto) relative to the workpiece table 3 along the stroke axis 15. In addition, a rotatory drive (not shown in detail) is operable to adjust a rotational position of the punch holder 8 and a rotational position of the die holder 10 independently of each other about a tool rotation axis 16, which is identical to the stroke axis 15.
Still referring to
During tool changing and workpiece processing operations, the drives 13, 14 of the punching/forming machine 1 are controlled by a numerical control unit 19. The numerical control unit 19 includes a storage 20 for storing tool data and a control device 21. The control device 21 is operable to calculate and control the raising, lowering, and rotational movements of the punch holder 8 and the die holder 10 based on the stored data related to the workpiece 4 and to the particular tool 12 being used during the processing operation.
a-2d illustrate a method of performing a punching stroke using the punching tool 12 (the punching die 11 of the punching tool 12 is not shown since the die 11 remains in a fixed location during the punching operation, as will be described in more detail below). A lower end of the punch 9 extends through a passage (e.g., a cylindrical passage) of a hold-down device 24 and towards the workpiece 4. The punch 9 is moved along the stroke axis 15 by the punch drive 13 (shown in
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The detection device 26 (shown in
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In the position shown in
The position of the stripper 25 and the distance between the upper surface 4a of the workpiece 4 and the stripper 25 is selected based on the thickness d of the workpiece 4. The distance should not be greater than the thickness d of the workpiece 4. In some embodiments, the thickness d of the workpiece 4 is stored in the numerical control unit 19 or in the storage 20. In some embodiments, the thickness d of the workpiece 4 is determined during processing of the workpiece 4. Although the distance is selected as half the thickness d/2 of the workpiece 4 in the example of
In some embodiments, a detector or a sensor device may be integrated with the stripper 25 to detect or aid in the detection of the reference position PR or the lifting of the stripper 25 from the upper surface 4a of the workpiece 4. In some embodiments, the detector or sensor may be an optical sensor. In some embodiments, the reference position PR or the lifting of the stripper 25 may be determined using a resistance measurement or a voltage measurement, since the lifting of the stripper 25 from the workpiece 4 interrupts the electrical contact between the two components.
Positioning the stripper 25 at a distance above the upper surface 4a of the workpiece 4 suitable for moving the workpiece part 4b away from the processing region can also be implemented for other embodiments of punching/forming tools. For example,
Referring particularly to
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Referring particularly to
Once the spring 32 reaches the resting position, the hold-down device 24 and the punch 9 are moved upward by the action of the spring force of the spring 33 until the punch 9 again reaches the starting position shown in
In order to push a workpiece part away from the processing region during the upward movement, the punch 9 and the ram 13a may be fixed in a position in which the stripper 25 is positioned at a distance of half of the thickness d/2 of the workpiece thickness d from the upper surface 4a of the workpiece 4. Accordingly, the numerical control unit 19, which knows the position of the ram 13a along the stroke axis 15 from data provided by a distance measurement device (not shown), makes reference to the position PR of the hold-down device 24. The position PR was determined at the configuration shown in
Thus, positioning the stripper 25 at a particular distance (e.g., based on the thickness d of the workpiece 4) along the stroke axis 15 from the upper surface 4a of the workpiece 4 while a workpiece part 4b is moved away from the processing region can significantly increase the reliability of such a process.
A number of embodiments have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. Accordingly, other embodiments are within the scope of the following claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 12169979.7 | May 2012 | EP | regional |
