Molding system

Abstract

A forming system (100) expands and deforms a metal material to perform forming. The forming system includes: a forming device (1) for performing forming; and at least one conveying device (110A-110D) for conveying the metal material. The conveying device conveys the metal material to the forming device (1) while holding the metal material. In the case of a pretreatment device (60) for performing forming, the conveying device (110A) conveys the metal material to the pretreatment device (60) while holding the metal material. During the period from the conveying step of conveying the metal material to a certain device to the processing step in a certain device, the metal material is continuously held by the conveying device and at least one of the devices.

Description

Technical Field

[0001] One embodiment of the present invention relates to a molding system. Background Technology

[0002] Conventionally, a molding system as described in Patent Document 1 is known. This molding system includes: a heating unit for heating a metal material; a fluid supply unit for supplying fluid to the heated metal material; and a molding die for molding the heated metal material. The molding apparatus brings the molding surface of the molding die into contact with the heated metal material, thereby shaping the metal material into a shape corresponding to the molding surface.

[0003] Previous technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2009-220141 Summary of the Invention

[0006] The technical problem to be solved by the invention

[0007] Here, the forming system described in Patent Document 1 expands and deforms the metal material to form it. In this type of forming system, the metal material needs to expand during forming, so it is impossible to form a reference hole for defining the reference position in a stage before the forming process. Even in the case where it is impossible to set such a reference hole, it is necessary to improve the accuracy of the product using the formed part.

[0008] One embodiment of the present invention was made to solve this problem, and its object is to provide a molding system that can improve the precision of products using molded parts.

[0009] means for solving technical problems

[0010] An embodiment of the present invention relates to a molding system that expands and deforms a metal material to perform molding. The molding system includes: a molding apparatus for performing molding; and at least one conveying device for conveying the metal material. The conveying device conveys the metal material to the molding apparatus while holding the metal material. In the case of a pretreatment device for performing molding, the conveying device conveys the metal material to the pretreatment device while holding the metal material. During the period from the conveying step of conveying the metal material to a certain device to the processing step in a certain device, the metal material is continuously held by the conveying device and at least one of the devices.

[0011] In the forming system, the transport device transports the metal material to the forming device while holding it. Furthermore, if a pretreatment device is present for pretreatment before forming, the transport device also transports the metal material to the pretreatment device while holding it. In contrast, during the period from the transport step where the metal material is transported from the transport device to the forming device until the processing step in that device, the metal material is continuously held by the transport device and at least one of the devices. That is, during the period from the transport step where the metal material is transported from the transport device to the forming device until the forming processing step in the forming device, the metal material is continuously held by the transport device and at least one of the forming devices. Furthermore, if a pretreatment device is present, during the period from the transport step where the metal material is transported from the transport device to the pretreatment device until the pretreatment step in the pretreatment device, the metal material is continuously held by the transport device and at least one of the pretreatment devices. In this case, if the metal material is positioned in a stage prior to the transport step, the forming system can perform the processing step while maintaining the aligned position of the metal material. That is, it can continuously suppress positional or phase shifts in the metal material in the forming device or pretreatment device and perform the forming or pretreatment. This improves the precision of products that use molded parts.

[0012] The forming system includes a positioning unit in a pretreatment device for positioning the metal material. A transport device holds the metal material in the positioning unit after it has been positioned. From the time the positioning unit is held by the transport device until the forming device performs the forming process, the metal material can be continuously held by one of the transport device, the forming device, or, if a pretreatment device is present. During this time, the forming system can perform the forming process in the forming device while maintaining the metal material in the aligned position in the positioning unit.

[0013] The molding system also includes a post-processing unit that processes the molded product formed by the molding unit. The molding unit marks the molded product, and the post-processing unit detects the marks formed during this process. Prior to the molding process, which involves expansion and deformation, it is impossible to form reference holes or similar features on the metal material. However, here, the molding unit marks the molded product after expansion and deformation. The marks serve to record precise relative positions with respect to the product shape. Therefore, in subsequent processes after the molding process, the post-processing unit can use the information based on the marks to perform high-precision processing. This improves the accuracy of products using the molded product.

[0014] One embodiment of the present invention relates to a molding system that expands and deforms a metal material to perform molding. The molding system includes: a molding apparatus for performing molding; and a post-processing apparatus for processing the molded article formed by the molding apparatus. The molding apparatus marks the molded article, and the post-processing apparatus detects the marks formed by the marking.

[0015] In the molding system, the molding unit marks the molded part, and the post-processing unit inspects the marks formed by these marks. In the stage prior to the molding process, which involves expansion and deformation, it is impossible to form reference holes or similar features on the metal material; however, here, the molding unit marks the molded part after expansion and deformation. The marks serve to record precise relative positions with respect to the product shape. Therefore, in subsequent processes after the molding process, the post-processing unit can use the information based on the marks to perform high-precision processing. This improves the accuracy of products using the molded parts.

[0016] The post-processing unit can detect markings and correct the processing position of the molded part based on the detection results before performing the prescribed processing. Thus, the post-processing unit can perform high-precision processing based on the detection results of the markings.

[0017] A forming system expands and deforms a metal material to form it. The forming system includes: a forming apparatus for forming; at least one conveying apparatus for conveying the metal material; and a post-processing apparatus for processing the molded article formed by the forming apparatus. The conveying apparatus conveys the metal material to the forming apparatus while holding it. If a pre-processing apparatus for pre-processing is present, the conveying apparatus conveys the metal material to the pre-processing apparatus while holding it. During the period from the conveying step where the conveying apparatus conveys the metal material to a certain apparatus to the processing step in that apparatus, the metal material is continuously held by the conveying apparatus and at least one of the apparatuses. The forming apparatus marks the molded article, and the post-processing apparatus detects the mark formed by the marking.

[0018] According to the molding system, in the molding system, a transport device transports metal material to the molding device while holding the metal material. Furthermore, if a pretreatment device is present for pretreatment before molding, the transport device transports the metal material to the pretreatment device while holding the metal material. In contrast, during the period from the transport step where the transport device transports the metal material to a certain device until the processing step in that device, the metal material is continuously held by the transport device and at least one of the devices. That is, during the period from the transport step where the transport device transports the metal material to the molding device until the molding processing step in the molding device, the metal material is continuously held by the transport device and at least one of the molding devices. Furthermore, if a pretreatment device is present, during the period from the transport step where the transport device transports the metal material to the pretreatment device until the pretreatment step in the pretreatment device, the metal material is continuously held by the transport device and at least one of the pretreatment devices. At this time, if the metal material is positioned in a stage prior to the transport step, the molding system can perform the processing step while maintaining the aligned position of the metal material. That is, it can continuously suppress positional or phase shifts of the metal material in the molding device or pretreatment device and perform molding or pretreatment. This improves the precision of products using molded parts. Furthermore, in the molding system, the molding device marks the molded part, and the post-processing device detects the marks formed by these marks. While it's impossible to form reference holes or similar features on the metal material before the molding process, which involves expansion and deformation, the molding device marks the molded part after expansion and deformation. These marks serve to record precise relative positions with respect to the product shape. Therefore, in subsequent processes after the molding process, the post-processing device can use the information based on these marks to perform high-precision processing. This further improves the precision of products using molded parts.

[0019] Invention Effects

[0020] According to one embodiment of the present invention, a molding system is provided that can improve the precision of products using molded articles. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the molding apparatus used in the molding system according to this embodiment.

[0022] Figure 2 This is an example of a conceptual diagram illustrating the structure of the molding system involved in this embodiment.

[0023] Figure 3 This is a schematic diagram showing the holding state of the metal tube materials in each device.

[0024] Figure 4 This is a schematic diagram showing the processing steps of the molded product after molding.

[0025] Figure 5 It is a cross-sectional view showing the markings on the forming device. Detailed Implementation

[0026] Hereinafter, preferred embodiments of the present invention will be described with reference to the accompanying drawings. Furthermore, in the drawings, the same or corresponding parts are labeled with the same symbols, and repeated descriptions are omitted.

[0027] Figure 1 This is a schematic diagram of the molding apparatus 1 used in the molding system 100 according to this embodiment. Figure 1 As shown, the forming apparatus 1 is an apparatus for forming heated metal material using a forming mold. In this embodiment, the forming apparatus 1 is a STAF forming apparatus that supplies fluid to the heated metal tube material so that it comes into contact with the forming surface of the forming mold for forming and quenching. In this embodiment, the forming apparatus 1 is provided on a horizontal plane. The forming apparatus 1 includes: a forming mold 2, a drive mechanism 3, a holding part 4, a fluid supply part 6, a cooling part 7, and a control part 8. In this specification, the metal tube material 40 (metal material) refers to a hollow article before the forming apparatus 1 completes the forming process. The metal tube material 40 is a tube material of quenchable steel. Furthermore, the direction of extension of the metal tube material 40 during forming in the horizontal direction is sometimes referred to as the "length direction," and the direction orthogonal to the length direction is referred to as the "width direction."

[0028] The forming mold 2 is a mold for forming the metal tube material 40 into a product, and it has a lower mold 11 and an upper mold 12 that are opposed to each other in the vertical direction. The lower mold 11 and the upper mold 12 are made of steel blocks. Recesses with forming surfaces of the metal tube material 40 are provided on the lower mold 11 and the upper mold 12 respectively. When the lower mold 11 and the upper mold 12 are in close contact with each other (closed mold state), each recess forms a space for forming the target shape of the metal tube material. Therefore, the surface of each recess becomes the forming surface of the forming mold 2. The lower mold 11 is fixed to the base 13 via a mold base or the like. The upper mold 12 is fixed to the sliding member of the drive mechanism 3 via a mold base or the like.

[0029] The drive mechanism 3 is a mechanism that moves at least one of the lower mold 11 and the upper mold 12. Figure 1 In this design, the drive mechanism 3 has a structure that moves only the upper mold 12. The drive mechanism 3 includes: a sliding member 21 that moves the upper mold 12 toward the lower mold 11 and the direction in which the upper mold 12 closes with each other; a pull-back cylinder 22, which acts as an actuator, and generates a force that pulls the sliding member 21 upward; a main cylinder 23, which acts as a drive source, and lowers the sliding member 21 and applies pressure; and a drive source 24 that applies a driving force to the main cylinder 23.

[0030] The retaining part 4 is a mechanism for holding the metal tube material 40 disposed between the lower mold 11 and the upper mold 12. The retaining part 4 includes a retaining member 26 and a retaining member 27 that hold the metal tube material 40 at one end along the length of the forming mold 2. The retaining members 26 and 27 on both sides along the length clamp the metal tube material 40 near its end from the vertical direction, thereby holding the metal tube material 40. Furthermore, grooves with shapes corresponding to the outer peripheral surface shape of the metal tube material 40 are formed on the upper surface of the retaining member 26 and the lower surface of the retaining member 27. A drive mechanism (not shown) is provided on the retaining members 26 and 27, allowing the retaining members 26 and 27 to move independently in the vertical direction.

[0031] The fluid supply unit 6 is a mechanism for supplying high-pressure fluid into a metal tube material 40 held between the lower mold 11 and the upper mold 12. The fluid supply unit 6 supplies high-pressure fluid to the heated metal tube material 40, causing it to expand. The fluid supply unit 6 is located at both ends of the molding die 2 along its length. The fluid supply unit 6 includes: a nozzle 31 for supplying fluid into the metal tube material 40 through an opening at one end; a drive mechanism 32 for moving the nozzle 31 back and forth relative to the opening of the metal tube material 40; and a supply source 33 for supplying high-pressure fluid into the metal tube material 40 via the nozzle 31. The drive mechanism 32 keeps the nozzle 31 in close contact with the end of the metal tube material 40 to ensure a seal during fluid supply and during venting, and separates the nozzle 31 from the end of the metal tube material 40 at other times. Alternatively, the fluid supply unit 6 can also supply high-pressure air or an inert gas as the fluid. Furthermore, the fluid supply unit 6 and the holding unit 4, which has a mechanism for moving the metal tube material 40 in the up-down direction, can be provided as the same device. In this case, the base member 38 supporting the fluid supply unit 6 and the holding unit 4 can be connected by the connecting member 39.

[0032] The cooling section 7 is a mechanism for cooling the molding die 2. By cooling the molding die 2, the cooling section 7 can rapidly cool the expanded metal tube material 40 when it comes into contact with the molding surface of the molding die 2. The cooling section 7 includes: a flow path 36 formed inside the lower die 11 and the upper die 12; and a water circulation mechanism 37 that supplies cooling water to the flow path 36 and circulates it.

[0033] The control unit 8 is a device for controlling the entire molding apparatus 1. The control unit 8 controls the drive mechanism 3, the holding unit 4, the fluid supply unit 6, and the cooling unit 7. The control unit 8 repeatedly performs the action of molding the metal tube material 40 by the molding die 2.

[0034] Specifically, the control unit 8 controls the timing of transport by a transport device such as a robotic arm, thereby placing the metal tube material 40 between the lower mold 11 and the upper mold 12 in the open state. Furthermore, the control unit 8 controls the actuator of the holding unit 4, etc., so that the metal tube material 40 is supported by the holding members 26 on both sides in the length direction, and then the holding members 27 are lowered to clamp the metal tube material 40.

[0035] The control unit 8 controls the drive mechanism 3 to lower the upper mold 12 and bring it closer to the lower mold 11, thereby closing the molding die 2. Meanwhile, the control unit 8 controls the fluid supply unit 6 to seal the openings at both ends of the metal tube material 40 using nozzles 31 and supply fluid. As a result, the softened metal tube material 40 expands and contacts the molding surface of the molding die 2. Furthermore, the metal tube material 40 is molded to the same shape as the molding surface of the molding die 2. Additionally, when forming a flanged metal tube, a portion of the metal tube material 40 is inserted into the gap between the lower mold 11 and the upper mold 12, and then the mold closing process continues, flattening the insertion portion to form a flange. If the metal tube material 40 contacts the molding surface, the molding die 2, cooled by the cooling unit 7, rapidly cools the metal tube material 40, thereby quenching the metal tube material 40.

[0036] As described above, the molding apparatus 1 expands and deforms the metal tube material 40 to perform molding. Therefore, it is impossible to have a structure where drilling holes in the metal tube material 40 before it is expanded by the molding apparatus 1 would lead to fluid leakage. Therefore, it is impossible to form positioning holes in the metal tube material 40 before molding. Therefore, the molding system 100 according to this embodiment has a structure for molding the metal tube material 40 using the molding apparatus 1 while it is positioned.

[0037] Figure 2 This is an example of a conceptual diagram illustrating the structure of the molding system 100 according to this embodiment. For example... Figure 2 As shown, the forming system 100 includes a metal tube material preparation area E1, a heating area E2, a forming area E3, an agglomeration area E4, a processing area E5, and a finishing area E6. Furthermore, the forming system 100 includes: a positioning part 50 in the metal tube material preparation area E1; a heating device 60 in the heating area E2; a forming device 1 in the forming area E3; an agglomeration part 70 in the agglomeration area E4; an inspection device 81, an oxide scale removal device 82, and an agglomeration part 83 in the processing area E5; a post-processing device 90 in the finishing area E6; and conveying devices 110A to 110D disposed in each area. The conveying devices 110A to 110D are composed of conveying devices such as robotic arms.

[0038] Metal tube material 40 is prepared in metal tube material preparation area E1. Furthermore, in metal tube material preparation area E1, [the process involves] utilizing... Figure 3 The positioning part 50 shown in (a) is used to position the metal tube material 40. For example, as shown in (a) Figure 3 As shown in (a), the positioning part 50 positions the metal tube material 40 using three-point support. Specifically, the positioning part 50 includes: support parts 51A and 51B, supporting both ends of the metal tube material 40; and support part 51C, supporting the central position of the metal tube material 40 in the longitudinal direction. For example, the positioning part 50 can determine the phase of the metal tube material 40 using the support parts 51A, 51B, and 51C. Furthermore, in the positioning part 50, positioning in the longitudinal direction is achieved by abutting one end of the metal tube material 40 against the wall part 52.

[0039] Return to Figure 2 The metal tube material 40, positioned by the positioning part 50, is transported by the conveying device 110A to the heating device 60 in the heating zone E2. In the heating zone E2, the metal tube material is heated by the heating device 60. Figure 3 As shown in (c), the heating device 60 includes two sets of electrodes 61 and 62. One set of electrodes 61 and 62 clamps and holds one end of the metal tube material 40. The other set of electrodes 61 and 62 clamps and holds the other end of the metal tube material 40. The heating device 60 is a mechanism that heats the metal tube material 40 by energizing it via the electrodes 61 and 62. The heating device 60 allows a high current to flow between the one set of electrodes 61 and 62 and the other set of electrodes 61 and 62. As a result, current flows axially through the metal tube material 40, and due to the resistance of the metal tube material 40 itself, the metal tube material 40 heats up based on Joule heating.

[0040] Return to Figure 2 The metal tube material 40, heated by the heating device 60, is transported by the conveying device 110B to the forming device 1 in the forming area E3. In the forming area E3, the metal tube material 40 is formed by the forming device 1. This forms a molded product 41 (see reference). Figure 4 ).

[0041] Molded articles 41 formed by molding device 1 are collected in collection section 70 of collection area E4 by transport device 110C. Collection section 70 is a device for collecting multiple molded articles 41. Figure 4 As shown in (a), in the aggregation section 70, the transport device 110C holds the molded article 41 formed by the molding device 1 and loads it onto the aggregation trolley 71. The transport device 110C repeats this action to accumulate the molded article 41 on the aggregation trolley 71, thereby performing aggregation.

[0042] Return to Figure 2The operator transports the assembled trolley 71, which holds the molded products 41 in the assembly section 70, to the inspection device 81 in the processing area E5. The inspection device 81 inspects the molded products 41, checking their shape and other features, and displays errors for any products 41 that do not meet specified standards. Next, the operator transports the qualified molded products 41 to the oxide scale removal device 82. The oxide scale removal device 82 removes the oxide scale formed on the molded products 41 during molding. The oxide scale removal device 82 removes the oxide scale, for example, by shot peening or wet sandblasting. The operator then collects the oxide scale-removed molded products 41 on the assembly trolley in the assembly section 83.

[0043] The molded part 41 in the aggregation section 83 is transported by the conveying device 110D to the post-processing device 90 in the processing area E6. For example... Figure 2 As shown, the post-processing device 90 in processing area E6 irradiates the molded product 41 with a laser to perform drilling, notch formation, and cutting. Figure 4 As shown in (b) and (c), the post-processing apparatus 90 includes a laser head 91 (processing unit). The post-processing apparatus 90 moves the laser head 91 while irradiating the molded product 41 with a laser from the laser head 91, according to the processing requirements.

[0044] The molding system 100 of this embodiment has the following function: during the period until molding is performed by the molding device 1, the relative position and relative phase of the positioned metal tube material 40 are kept unchanged.

[0045] Specifically, in the forming system 100, during the period from the transport step where the transport devices 110A and 110B transport the metal tube material 40 to the processing step in one of the devices 1 and 60, the metal tube material 40 is continuously held by at least one of the transport devices 110A and 110B and the device 1 and 60. After the positioning part 50 is held by the transport device 110A until it is formed by the forming device 1, the metal tube material 40 is continuously held by one of the transport devices 110A and 110B, the forming device 1, and the heating device 60.

[0046] More specifically, such as Figure 3As shown in (b), the conveying device 110A holds the metal tube material 40 after it has been positioned on the positioning part 50 by clamping it with the holding members 101 and 102. At this time, the conveying device 110A is configured such that when holding the metal tube material 40 on the positioning part 50, the position or angle of the metal tube material 40 relative to the holding members 101 and 102 remains unchanged before and after holding. The conveying device 110A conveys the metal tube material 40 to the heating device 60 while it is held by the holding members 101 and 102. Furthermore, the conveying device 110A does not release the holding of the metal tube material 40 or change the holding state (e.g., change the holding position or angle) during the conveying process.

[0047] like Figure 3 As shown in (c), the conveying device 110A positions itself relative to the heating device 60 while holding the metal tube material 40. At this time, the conveying device 110A positions itself based on information such as the holding position or angle of the metal tube material 40. Once the positioning by the conveying device 110A is complete, the heating device 60 uses electrodes 61 and 62 to hold both ends of the metal tube material 40. Figure 3 As shown in (d), once the electrodes 61 and 62 are held, the holding part 100A releases the metal tube material 40 and the holding parts 101 and 102 return to the positioning part 50.

[0048] Next, the transport device 110B uses the holding members 101 and 102 to clamp the heated metal tube material 40, thereby holding the metal tube material 40. At this time, the transport device 110B is configured such that the position or angle of the metal tube material 40 relative to the holding members 101 and 102 remains unchanged when holding the metal tube material 40 on the heating device 60. Once the holding by the transport device 110B is completed, the heating device 60 releases its grip based on the electrodes 61 and 62. The transport device 110B transports the metal tube material 40 to the forming device 1 while it is held by the holding members 101 and 102. Furthermore, the transport device 110B does not release the grip of the metal tube material 40 or change the gripping state (e.g., change the gripping position or angle) during the transport process.

[0049] like Figure 3 As shown in (e), the conveying device 110B positions itself relative to the forming device 1 while holding the metal tube material 40. At this time, the conveying device 110B is configured such that the position or angle of the metal tube material 40 relative to the holding members 101 and 102 remains unchanged before and after holding the metal tube material 40. Once the positioning by the conveying device 110B is complete, the forming device 1 holds both ends of the metal tube material 40 using the holding members 26 and 27. Figure 3As shown in (f), once the gripping is complete, the gripping part 100B releases the gripping of the metal tube material 40, and the gripping parts 101 and 102 return to the heating device 60 side. The metal tube material 40 disposed on the molding device 1 is molded into a molded product 41.

[0050] Furthermore, the molding device 1 marks the molded article 41. For example... Figure 5 As shown, the molding apparatus 1 has a marking section 120. The marking section 120 marks the outer peripheral surface of the molded article 41. Taking the case of marking with a pin as an example, the marking section 120 includes a pin 121, a pin support mechanism 122, a hydraulic chamber 123, and a working oil supply section 124. The pin 121 is disposed in the lower mold 11 and can reciprocate in the vertical direction. When not marking, the pin 121 is contained in the lower mold 11 and does not protrude from the molding surface 11a. When marking, the pin 121 protrudes from the molding surface 11a. The pin support mechanism 122 is a mechanism that supports the pin 121 in the lower mold 11. The pin support mechanism 122 supports the pin 121 and can reciprocate in the vertical direction. Furthermore, the pin support mechanism 122 includes a spring member 122a. When the pin 121 protrudes from the molding surface 11a, the spring member 122a applies a spring force in the direction that returns the pin 121 to its original position. The hydraulic chamber 123 is an internal space formed within the lower mold 11. The base end of the pin 121 is exposed within the hydraulic chamber 123. The working oil supply unit 124 supplies working oil to the hydraulic chamber 123.

[0051] Therefore, if the working oil supply unit 124 supplies working oil to the hydraulic chamber 123, the base end of the pin 121 is subjected to pressure, and the pin 121 protrudes from the molding surface 11a. This forms a mark based on a recess or through hole on the outer peripheral surface of the molded article 41. If the working oil is discharged from the hydraulic chamber 123, the pressure on the base end of the pin 121 is released, and the pin 121 returns to its original position. Furthermore, the hydraulic mechanism described above does not necessarily need to be built into the lower mold 11; it can also be built into the mold base or the stamping device. Additionally, the timing of the pin 121 protruding from the molding surface and being marked is not particularly limited. However, the pin 121 can be marked after molding is completed and the temperature of the molded article 41 has dropped to a certain level. At this time, the marking can be applied after the heated and expanded molded article 41 has cooled and contracted.

[0052] During molding in the molding apparatus 1, the marking portion 120 accommodates the pin 121 within the lower mold 11. After molding is complete, the marking portion 120 causes the pin 121 to protrude from the molding surface 11a, pressing the pin 121 against the molded article 41. This imparts a mark to the molded article 41. The marking portion 120 can be provided, for example, at locations corresponding to the two ends of the molded article 41 or at the center of the molded article 41 in the lower mold 11. Furthermore, the marking portion 120 can also be provided at locations corresponding to the two ends of the molded article 41 or at the center of the molded article 41 in the upper mold 12. However, the number and position of the marking portions 120 are not particularly limited. For example, it is preferable to provide two or more marking portions 120, including those positioned as far apart as possible. Regarding the marking, any marking that allows for coordinate determination is acceptable; for example, in addition to pin-based engravings, intersecting lines based on scratches or drilled holes can be used.

[0053] like Figure 4 As shown in (b) and (c), the post-processing unit 90 detects the mark MK formed by marking. Furthermore, the post-processing unit 90 detects the mark MK and performs positional correction between the laser head 91 and the molded product 41 based on the detection result. Figure 4 As shown in (b), the post-processing apparatus 90 includes a detection unit 92 for detecting the mark MK. The detection unit 92 is, for example, a camera. The detection unit 92 detects the position of the mark MK based on the captured image. Then, the post-processing apparatus 90 calculates the relative offset between a preset processing trajectory and the molded article 41 held within the post-processing apparatus 90 based on the detected position of the mark MK, and calculates a correction amount for the processing trajectory. Then, as... Figure 4 As shown in (c), if there is an offset between the laser head 91 and the cutting line CL, the post-processing device 90 moves the laser head 91 to the position of the cutting line CL to correct the offset.

[0054] Next, the effects of the molding system 100 according to this embodiment will be explained.

[0055] The forming system 100 is a system that expands and deforms a metal tube material 40 to perform high-pressure gas expansion forming. In this type of forming system 100, the metal material needs to expand during forming, so it is impossible to form a reference hole for defining the reference position in a stage before the forming process. If a reference hole can be provided, the metal tube material 40 can be easily positioned by inserting a positioning pin or the like into the reference hole, and the reference hole can also be used to position the molded product 41 during processing in the post-processing device 90. However, in high-pressure gas expansion forming, if such a reference hole is formed on the metal tube material 40, the high-pressure gas will leak from the reference hole, making forming impossible.

[0056] In contrast, the molding system 100 of this embodiment expands and deforms the metal tube material 40 to perform molding. The molding system 100 includes: a molding device 1 for performing molding; and a conveying device for conveying the metal tube material 40. The conveying device conveys the metal tube material 40 to the molding device 1 while holding the metal tube material 40. In the presence of a heating device (pretreatment device) for pretreatment of molding, the metal tube material 40 is conveyed to the heating device 60 while holding the metal tube material 40. During the period from the conveying step of the conveying device to the processing step in the device 1 or 60, the metal tube material 40 is continuously held by the conveying device and at least one of the devices 1 or 60.

[0057] In the forming system 100, during the period from the transport step where the transport device transports the metal tube material 40 to the processing step in one of the devices 1 or 60, the metal tube material 40 is continuously held by the transport device and at least one of the devices 1 or 60. That is, during the period from the transport step where the transport device 110B transports the material to the forming device 1 to the forming processing step in the forming device 1, the metal tube material 40 is continuously held by the transport device 110B and at least one of the forming devices 1. Furthermore, if the heating device 60 is present, during the period from the transport step where the transport device 110A transports the material to the heating device 60 to the heating step in the heating device 60, the metal tube material 40 is continuously held by the transport device 110A and at least one of the heating devices 60. At this time, if the positioning of the metal tube material 40 is performed in the stage before the transport step, the forming system 100 can perform the processing step while maintaining the aligned position of the metal tube material 40. That is, it is possible to continuously prevent the metal tube material 40 in the molding apparatus 1 or heating apparatus 60 from undergoing positional or phase shifts, and to perform molding or heating processes. As a result, the accuracy of products using the molded article 41 can be improved.

[0058] The forming system 100 includes a positioning unit 50 in a pre-processing unit for positioning the metal tube material 40. Transport devices 110A and 110B hold the metal tube material 40 after it has been positioned in the positioning unit 50. From the time the positioning unit 50 is held by the transport devices 110A and 110B until it is formed by the forming device 1, the metal tube material 40 is continuously held by one of the transport devices 110A and 110B, the forming device 1, or, if a heating device 60 is present, the heating device 60. During this time, in the transport process of the transport device 110A, the heating process of the heating device 60, the transport process of the transport device 110B, and the forming process of the forming device 1, the metal tube material 40 can be continuously prevented from shifting position or phase, thereby ensuring repeatability. Therefore, the forming system 100 can perform the forming process in the forming device 1 while maintaining the metal tube material 40 in the aligned position in the positioning unit 50.

[0059] The molding system 100 of the embodiment expands and deforms the metal tube material 40 to perform molding. The molding system 100 includes: a molding device 1 for performing molding; and a post-processing device 90 for processing the molded article 41 formed by the molding device 1. The molding device 1 marks the molded article 41, and the post-processing device 90 detects the mark formed by the marking, performs a correction calculation of the processing position based on the mark position, and then performs the prescribed processing.

[0060] In the molding system 100, the molding device 1 marks the molded product 41, and the post-processing device 90 detects the marks formed by the marking. Before the molding process accompanied by expansion and deformation, it is impossible to form reference holes or the like on the metal tube material 40; however, here, the molding device 1 marks the molded product 41 after expansion and deformation. The marks serve to record a precise relative position with respect to the product shape. Therefore, in subsequent processes after the molding process, the post-processing device 90 can use the information based on the marks to perform high-precision processing. Furthermore, the post-processing device 90 uses the detection results of the marks to process reference holes or notches, thereby enabling the use of the same assembly process as conventional vehicle body assembly processes. In particular, in this embodiment, as described above, the molding device 1 can perform molding while maintaining the positioning state in the positioning section 50. Therefore, the molding device 1 can mark the molded product 41 in a state where positional and phase shifts are suppressed. Therefore, the post-processing device 90 can use the positional information of the marks recorded at precise relative positions with respect to the mold forming surface to perform processing. This improves the accuracy of the product using the molded product 41.

[0061] The post-processing unit 90 detects the markings and, based on the detection results, performs relative position correction for processing, using the marking positions on the molded part 41 as recorded at precise relative positions, and then performs the prescribed processing. Thus, the post-processing unit 90 can perform high-precision processing based on the marking detection results.

[0062] A forming system forms a metal material by expanding and deforming it. The forming system includes: a forming apparatus for forming; a conveying apparatus for conveying the metal material; and a post-processing apparatus for processing the molded article formed by the forming apparatus. The conveying apparatus conveys the metal material to the forming apparatus while holding it. If a pre-processing apparatus for pre-processing is present, the conveying apparatus conveys the metal material to the pre-processing apparatus while holding it. During the period from the conveying step where the metal material is conveyed to a certain apparatus to the processing step in that apparatus, the metal material is continuously held by the conveying apparatus and at least one of the apparatuses. The forming apparatus marks the molded article, and the post-processing apparatus detects the mark formed by the marking.

[0063] According to this molding system, the same effect as the molding system described above can be achieved.

[0064] The present invention is not limited to the embodiments described above.

[0065] For example, a pretreatment device may not be present upstream of the molding device. That is, a heating device may also be absent. In this case, the molding device has electrodes for heating. Furthermore, a device other than a heating device may also be present as a pretreatment device.

[0066] The handling device is not limited to robotic arms or the like. In other words, any device capable of handling a metal tube material while maintaining at least its position and phase is acceptable.

[0067] The marking mechanism is not limited to the embodiments described above. For example, in the embodiments described above, marking is not performed during molding, but rather after molding is completed, the pin is driven by a drive mechanism to perform the marking. However, this drive mechanism can be omitted, and a structure in which the pin is always upright on the molding surface can be used. In this case, marking is performed simultaneously with the contact between the metal tube material and the molding surface. In addition, if a drive mechanism is provided, marking can be performed after the product shape has frozen, with less impact from cooling shrinkage and other factors.

[0068] The post-processing unit can also detect markings using methods other than taking pictures with a camera. For example, the post-processing unit can also detect markings using contact sensors or the like.

[0069] For example, an apparatus for high-pressure gas expansion molding is illustrated as a molding device; however, it is not particularly limited as long as the molding method involves molding through expansion and deformation. For example, molding methods based on internal high-pressure molding or the like can also be used.

[0070] The processing section is not limited to post-processing equipment; it can also employ equipment based on other processing methods.

[0071] Symbol Explanation

[0072] 1-Forming device, 60-Heating device (pre-treatment device), 90-Post-processing device, 91-Laser head (processing section), 100-Forming system, 110A, 110B, 110C, 110D-Transfer device.

Claims

1. A forming system that expands and deforms a metal tube material to perform forming, said forming system being characterized by comprising: The molding device performs the molding; and At least one conveying device is used to convey the metal tube material. The conveying device conveys the metal tube material to the forming device while holding the metal tube material in place; The forming system also includes a pretreatment device for pretreatment of the forming process, and the conveying device conveys the metal tube material to the pretreatment device while holding the metal tube material. During the period from the transport step where the metal tube material is transported by the transport device to the processing step in one of the forming device and the pretreatment device, the metal tube material is continuously held by the one device and at least one of the transport devices. A portion of the pretreatment apparatus also includes a positioning section for positioning the metal tube material. The conveying device holds the metal tube material in the position after it has been positioned in the positioning section. From the time the metal tube material is held by the positioning part by the conveying device until it is formed by the forming device, the metal tube material is continuously held by either the conveying device or the forming device, so that the relative position and relative phase of the positioned metal tube material remain unchanged. The conveying device has a gripping component that keeps the position or angle of the metal tube material relative to the gripping component unchanged before and after gripping during the conveying process. After the metal tube material held by the conveying device is held by one of the devices, the conveying device releases its grip on the metal tube material.

2. The molding system according to claim 1, characterized in that, It also includes a post-processing device, which processes the molded articles produced by the molding device. The molding device marks the molded article. The post-processing device detects the marks formed by marking.

Images