Production arrangement

Abstract

Manufacturing arrangement (10), configured for the production of a roller tube (81) and an axle shaft (82) of a conveyor roller (8) and for providing the axle shaft (82), arranged loosely inside the roller tube (81); in particular wherein a length (L) of the shaft (82) is greater than a length (I) of the tube (81); the manufacturing arrangement (10) comprises: - a pipe line (20) set up for the production of a coiled tube (81) from raw material for coiled tube (81r), - a wavy line (30) designed for the manufacture of an axle shaft (82) from raw material for axle shaft (82r), - an assembly line (40) set up for introducing the axle shaft (82) into the roller tube (81).

Description

[0001] The invention relates to a manufacturing arrangement for at least the partial production of a conveyor roller.

[0002] Conveyor rollers, especially idle rollers without an integrated drive motor, consist of a roller tube and an axle shaft that runs completely through the tube. Although conveyor rollers always share the same basic design, the variety of combinations is very high.

[0003] Manufacturing equipment for rollers and the like is described, for example, in DE 201 03 367 U1, DE 88 08 519 U1 and DE 10 2016 112 051 A1.

[0004] The object of the present invention is to provide an improved method for manufacturing a conveyor roller. This object is achieved by a manufacturing arrangement according to claim 1; embodiments are the subject of the dependent claims and the description.

[0005] The invention proposes to manufacture the axle shaft and the roller tube directly and parallel to each other and to assemble them together immediately after their manufacture.

[0006] The roller tube and axle shaft are manufactured directly from the raw material as needed, so that no stock of tubes and shafts is required.

[0007] In particular, the manufacturing arrangement is designed to change the configuration of the manufactured tubes and shafts during operation, especially their length and / or diameter.

[0008] An embodiment of the invention is explained in more detail below with reference to the figures: Fig. Figure 1 shows a production zone in perspective view; Fig. Figure 2 shows a longitudinal section of an idle roller of the conveying zone according to Fig. 1; Fig. Figure 3 shows three examples of different wave configurations in longitudinal section; Fig. Figure 4 shows a schematic representation of a manufacturing arrangement according to the invention; Fig. Figure 5 shows a detailed schematic representation of the pipe line of the manufacturing arrangement according to Fig. 4; Fig. Figure 6 shows a detailed schematic representation of the wave line of the manufacturing arrangement according to Fig. 4; Fig. Figure 7 shows a table with work cycles, input / output values ​​and buffer allocation within the pipeline according to Fig. 5 or the wavy line according to Fig. 6; Fig. Figure 8 shows a diagram for the table according to Fig. 7.

[0009] Fig. Figure 1 shows an exemplary conveying zone 2 in a perspective view, comprising several conveying rollers 8 which are driven together. The rollers are attached to a common frame 6. For this purpose, one of the conveying rollers is designed as a motorized conveying roller 8M. The motorized conveying roller 8M is driven by a motor, in particular a three-phase motor, which is arranged inside the conveying roller 8M. The remaining rollers 8 are idle rollers without an integrated drive motor. The conveying rollers 8 of a conveying zone 2 are connected to each other via one or more drive couplers, for example a drive belt, and are driven together by the motorized conveying roller 8M. A conveyed object 9 is conveyed linearly along a conveying direction d from an inlet I to an outlet O.

[0010] A presence sensor 5 can detect the presence of a conveyed object 9 located in conveying zone 2. The presence sensor 5 does not need to cover the entire conveying zone 2; it is sufficient if the presence of a conveyed object 9 is detected by the presence sensor 5 in a sub-area of ​​conveying zone 2. The presence sensor 5 generates a sensor signal that is connected to a zone controller (not shown) via a signal line (not shown).

[0011] Fig. Figure 2 shows an exemplary idle roller 8 in longitudinal view. The roller 8 has a roller tube 81 which is rotatably mounted about an axle shaft 82 via a bearing 83. A bearing housing 84 is attached to the roller tube 81. An end cap 85, which is attached to the axle shaft 82, covers the bearing 83.

[0012] The in Fig. The idle roller 8 shown in section 2 is merely one example of a multitude of embodiments: For example, the installation length L of the roller can have any value between 100 mm and 1600 mm.

[0013] The outer diameter D of the roller tube can, for example, take on the following discrete values: 30, 40, 50, 60 mm.

[0014] The diameter d of the axle shaft can, for example, take on the following discrete values: 8, 10, 12, 14 mm.

[0015] The axle shaft 82 can, for example, have the following characteristics (see Fig. 3): The axle shaft 82 can have a circular or hexagonal cross-section.

[0016] The axle shaft 82 can have a chamfer 821.

[0017] The axle shaft 82 can have a threaded section 822 at one end.

[0018] Fig. Figure 4 shows a schematic representation of a manufacturing arrangement 10, which is used to produce at least parts of the previously described idler roller 8. The manufacturing arrangement 10 comprises a pipe line 20, a wave line 30, and an assembly line 40.

[0019] In pipe line 20, raw material for coiled pipe 81r is stored in a warehouse 21. The raw material 81r comprises pipes with a length of approximately 2–5 m and varying diameters. Depending on the current order, the appropriate raw material is selectively taken from warehouse 21 and fed via a feeder 22 to a pipe processing unit 23. The pipe processing unit 23 processes the raw material 81r and provides finished coiled pipes 81 at a pipe outlet 24.

[0020] In the wave line 30, raw material for axle shaft 82r is provided in a storage area 31. The raw material 82r comprises shafts with a length of approximately 2–5 m and varying diameters. Depending on the current order, the appropriate raw material 82r is selectively taken from storage area 31 and fed via a feeder 32 to a shaft machining unit 33. The shaft machining unit 33 processes the raw material 82r and provides finished axle shafts 82 at a shaft output 34.

[0021] The finished coiled tubes 81 are fed to a tube feeder 41 of the assembly line 40. Alternatively, the tube feeder 41 can be identical to the tube outlet 24.

[0022] The finished axle shafts 82 are fed to a shaft feeder 42 of the assembly line 40. Alternatively, the shaft feeder 42 can be identical to the shaft output 34.

[0023] In an assembly process 43 of the assembly line 40, the finished axle shafts 82 are inserted into the finished roller tubes 81 and made available at an assembly output 44.

[0024] From assembly outlet 44, the assembled pipes and shafts are transferred to a storage area 50.

[0025] The transfer of raw materials from storage 21, 31 to feeders 22, 32 can be automatic or manual. Similarly, the transfer of assembled roller tubes 81 and axle shafts 82 from assembly output 44 to storage 50 can be automatic or manual.

[0026] All steps between inputs 22, 32 and the output are performed automatically and, in particular, in an unchanged sequence.

[0027] An unchanged sequence means that a pipe or shaft section that enters machining 23, 33 first also leaves the assembly process first. A pipe or shaft section that enters machining 23, 33 second leaves the assembly process after the section that entered first.

[0028] A control unit 11 automatically controls the operation of the production arrangement 10.

[0029] Fig. Figure 5 shows the pipe line 20 in a more detailed representation. The pipe processing includes a sawing station 231, to which the raw material for coiled pipe 81r is transferred from the feeder 22. There, the pipe material is sawn to the final length required for the intended conveyor roller, so that finished coiled pipes 81 are produced.

[0030] The coiled tube 81 is then fed to a tube buffer station 232, where several tubes are temporarily stored and await further processing steps. Downstream of the buffer station, the coiled tubes 81 are transferred to a tube end processing station 233. The tube end processing station 233 comprises one or more subunits 233a, b, c, in which the coiled tube 81 undergoes processing. For example, in a first processing unit 233a, the tube can be drilled or chamfered at the tube ends. In a second processing unit 233b, the coiled tube 81 can be measured. In a third processing unit 233c, the tube 81 can be cleaned, particularly to remove chips. Depending on the desired design of the coiled tube, further finishing steps are also possible.

[0031] Fig. Figure 6 shows the wave line 30 in a more detailed representation. The shaft processing includes a sawing station 331, to which the raw material for the axle shaft is transferred from the feeder 32. There, the shaft material is sawn to the final length required for the intended conveyor roller, so that finished axle shafts 82 are produced.

[0032] The axle shaft 82 is then fed to a shaft buffer station 332, where several shafts are temporarily stored and await further processing steps. Downstream of the buffer station, the axle shafts 82 are transferred to a shaft end processing station 333. The shaft end processing station 333 comprises one or more subunits 333a, 333b, and 333c, in which the axle shaft 82 undergoes processing. For example, in a first processing unit 333a, the axle shaft can be labeled and measured. In a second processing unit 333b, the axle shaft 82 can be chamfered to form a chamfer 821, and / or a centering bore can be machined into the shaft ends. In a third processing unit 333c, an external thread 822 or an internal thread can be cut into the ends of the axle shaft 82. Depending on the desired design of the axle shaft, further finishing steps are also possible.

[0033] Of particular relevance are buffer stations 232 and 332, which are described below with reference to the Fig. 7 and Fig. 8. The following description applies to the pipe buffer station 232 and / or the shaft buffer station 332.

[0034] The production arrangement 10 operates with a higher-level work cycle of, for example, a maximum of 5 seconds. Within each cycle, a roller tube 81 or an axle shaft 82 is processed in one of the finishing units 233a,b,c, 333a,b,c, including the transfer to the next processing station.

[0035] This is in the table ( Fig. 7) and in the associated diagram ( Fig.Figure 8) illustrates a sequence of work cycles, starting with cycle number 50 and ending with cycle number 80 (column C1). According to column C5, the finishing station delivers one unit in each cycle. Therefore, one unit must be transferred to the input of the finishing station (column C4) in each cycle.

[0036] In cycle 50, all fifteen buffer positions are occupied (column C3), resulting in a buffer occupancy of 100%. As long as the occupancy status is at least "1", the finishing station is operational. As soon as the occupancy status reaches "0", the finishing station will no longer be operational in the next cycle.

[0037] In cycles 50 and 51, the sawing station delivers one unit per cycle (column C2). Consequently, the buffer station receives precisely the number of units in each cycle that are required by the downstream finishing station and passed on to it from the buffer station.

[0038] Control unit 11 manages the production line based on order O12, which is provided by order management system 12. Order O12 contains all the information required for control, enabling the control unit to operate the production line in such a way that the desired products are available at the assembly output.

[0039] In particular, order 012 contains information on the raw materials to be used in the next operating period, which differ from the raw materials used in the previous operating period.

[0040] According to the order, a different type of raw material is to be used from cycle 52 onwards in cycles 52 and 64. For example, this new type of material may be characterized by a different pipe or shaft diameter, a different cross-section (e.g. round or hexagonal for the axle shaft), a different material length, or a different material type.

[0041] Due to the changeover to a new raw material, the feeders 22, 32 and / or the sawing stations 231, 331 must be set up for the new material. This setup cannot be done in a single cycle, but typically takes up to about one minute.

[0042] The units available in buffer stations 232 and 332 ensure that the finishing station can continue operating for the next 15 cycles. During these 15 cycles, the feeders 22 and 32 and / or the sawing stations 231 and 331 are set up for the new material.

[0043] From cycle 52 onwards, the sawing station no longer delivers units per cycle. However, the buffer continues to deliver one unit per cycle to the finishing station, as required by it, thus reducing the buffer capacity by one unit in each cycle.

[0044] After 13 cycles, i.e., at cycle 65, the feeder and / or saw station are operational again, and the buffer capacity is reduced to two units. Now the feeder and saw station operate at an increased output rate of two units per cycle. Accordingly, the buffer capacity increases by one unit in each cycle. At cycle 78, the buffer capacity has risen again to 15 units (100% buffer capacity).

[0045] The operation of the wave line 30 is synchronized with the operation of the pipe line 20, ensuring that an axle shaft 82, provided at the wave outlet 34, always matches a roller tube 81, provided at the pipe outlet 24. If a rejected part is detected in the pipe line, it is not transferred to the assembly line 40 for assembly with its corresponding axle shaft. To prevent mismatches, the axle shaft 82 associated with the rejected tube 81 is also removed and not fed to the assembly line 40. The same applies if an axle shaft is identified as a rejected part; in this case, the corresponding roller tube 81, which matches the rejected axle shaft 82, is also removed before it enters the assembly line.

[0046] If a defective part is identified, the assembly control system is set up to initiate a remanufacturing of the removed defective part.

[0047] In one embodiment, the remanufacturing of the rejected part takes place immediately before or after a subsequent order, taking into account the raw materials intended for the subsequent order compared to those used for the remanufacturing. Typically, remanufacturing a rejected part requires only the production of a single part with a specific specification. Therefore, it is efficient to schedule the remanufacturing at a time when parts with similar raw materials are already being manufactured. For example, if the rejected part is a tube with a specific diameter, the remanufacturing occurs directly after the production of other tubes with the same diameter. Assembly can then use the same raw materials for the remanufacturing as for the parts manufactured immediately before or after the rejected part. Reference symbol list 2 Production Zone 5 presence sensors 6 frames 8 Conveyor roller (idle roller) 8M Motorized Reel 81 roller tube 81r Raw material for roll tube 82 Axle shaft 82r Raw material for axle shaft 821 phase 822 Thread section 83 warehouses 84 bearing housings 85 End cap 9 Funded Project L (Installation) Length D (outer) diameter of the pipe d diameter of the shaft Order 012 10 Production arrangement 11 Control 20 pipeline 21 storage areas for raw pipe material 22 Raw material feed for the pipe 23 Pipe processing 231 Pipe saw station 232 Pipe buffer station 233 Pipe end processing station 24 Pipe outlet 30 wavy line 31 bearings for shaft raw material 32 Raw material feed for the shaft 33 Shaft machining 331 Wave saw station 332 Wave buffer station 333 Shaft end machining station 34 Shaft output 40 assembly line 41 Pipe feed for assembly 42 Shaft feed for assembly 43 Assembly process 44 Assembly exit 50 bearings for assembled pipes and shafts QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] DE 201 03 367 U1

[0003] DE 88 08 519 U1

[0003] DE 10 2016 112 051 A1

[0003]

Claims

[1] Manufacturing arrangement (10) configured for the production of a roller tube (81) and an axle shaft (82) of a conveyor roller (8) and for providing the axle shaft (82), arranged loosely inside the roller tube (81); in particular wherein a length (L) of the shaft (82) is greater than a length (I) of the tube (81); the manufacturing arrangement (10) comprises: - a pipe line (20) set up for the production of a coiled tube (81) from raw material for coiled tube (81r), - a wavy line (30) designed for the manufacture of an axle shaft (82) from raw material for axle shaft (82r), - an assembly line (40) set up for introducing the axle shaft (82) into the roller tube (81). [2] Manufacturing arrangement (10) according to claim 1, characterized by , that a length (L81r) of the raw material for coiled tube (81r) is a multiple of the length (I) of the tube (81) and / or has a length of at least 2 m; and / or that a length (L82r) of the raw material for axle shaft (82r) is a multiple of the length (L) of the shaft (82) and / or has a length of at least 2 m. [3] Manufacturing arrangement (10) according to one of the preceding claims, characterized by , that the pipeline (20) includes: - a feed for raw material of the pipe (22), - a pipe sawing station (231), - a pipe end processing station (233), and - a pipe outlet (24); wherein the feed for raw material of the pipe (22) is set up to supply the raw material for coiled pipe (81r) to the pipe sawing station (231); wherein the pipe sawing station (231) is set up to saw the raw material for coiled pipe (81r) individually to a desired pipe length (I); wherein the pipe end processing station (233) is set up to perform end processing of the pipes (81), in particular the end processing is individually selected for an individual pipe; the pipes (81) are provided at the pipe outlet (24) after final processing. [4] Manufacturing arrangement (10) according to one of the preceding claims, characterized by , that the wavy line (30) includes: - a feed for raw material of the shaft (32), - a wave saw station (331), - a shaft end machining station (333), and - a wave output (34); wherein the feed for raw material of the shaft (32) is set up to feed the raw material for axle shaft (82r) to the shaft sawing station (331); wherein the shaft sawing station (331) is set up to saw the raw material for axle shaft (82r) individually to a desired wavelength (L); wherein the shaft finishing station (333) is set up to perform finishing of the shafts (82), in particular the finishing is individually selected for an individual shaft; wherein the shafts (82) are provided at the shaft outlet (34) after final processing. [5] Manufacturing arrangement (10) according to claim 3 or 4, characterized by , that in normal operation the finishing station (233, 333), in particular the tube finishing station and / or the shaft finishing station, is set up to provide a tube (81) and / or a shaft (82) at a predetermined cycle time. [6] Manufacturing arrangement (10) according to one of the preceding claims, characterized by , that in normal operation - the feed (22, 32), in particular the feed for raw material of the tube (22) and / or the feed for raw material of the shaft (32), and / or - the sawing station (231, 331), in particular the pipe sawing station (231) and / or the shaft sawing station (331), is set up to provide a pipe (81) and / or a shaft (82) within the specified time interval. [7] Manufacturing arrangement (10) according to one of the preceding claims, characterized by , that in the setup operation - the feed (22, 32), in particular the feed for raw material of the tube (22) and / or the feed for raw material of the shaft (32), and / or - the sawing station (231, 331), in particular the pipe sawing station (231) and / or the shaft sawing station (331), is set up not to provide a tube (81) and / or a shaft (82); wherein during this setup operation the downstream finishing station (233, 333) is set up to continue to provide a tube (81) and / or a shaft (82) within the specified cycle time. [8] Manufacturing arrangement (10) according to one of the preceding claims, characterized by , that between - the sawing station (231, 331), in particular the pipe sawing station (231) and / or the shaft sawing station (331), and - the finishing station (233, 333), in particular the tube finishing station and / or the shaft finishing station, a buffer station (232, 332), in particular a pipe buffer station (232) and / or a wave buffer station (332), is provided; wherein the buffer station (232, 332) is set up to provide a pipe (81) and / or a shaft (82) within the specified cycle time, independently of the output of the saw station (231, 331). [9] Manufacturing arrangement (10) according to one of the preceding claims, characterized by , that in the refilling operation - the feed (22, 32), in particular the feed for raw material of the tube (22) and / or the feed for raw material of the shaft (32), and / or - the sawing station (231, 331), in particular the pipe sawing station (231) and / or the shaft sawing station (331), is set up to provide more than one pipe (81) and / or one shaft (82) within the specified time interval; wherein in refill operation the finishing station (233, 333), in particular the tube finishing station and / or the shaft finishing station, is set up to provide a tube (81) and / or a shaft (82) within the specified cycle time; In particular, the output rate of the feeder (22, 32) and / or the saw station is greater than the output rate of the finishing station (233, 333) in refill mode. [10] Manufacturing arrangement (10) according to one of the preceding claims, characterized by , that the manufacturing arrangement (10) is set up to identify a tube (81) within the tube line (20) and / or a shaft (82) within the shaft line (30) as a reject part and, in particular, to remove the reject part from the manufacturing arrangement (10); that the manufacturing arrangement (10) is set up to identify a shaft (82) and / or a tube (81) within the other line (30, 20) that is intended for assembly with the identified rejected part and, in particular, to remove the identified shaft (82) and / or tube (81) from the manufacturing arrangement (10). [11] Manufacturing arrangement (10) according to claim 10, characterized by , that when a tube (81) or shaft (82) is identified as a rejected part: the manufacturing arrangement (10) is set up to automatically initiate a reproduction of the rejected part. [12] Manufacturing arrangement (10) according to claim 11, characterized by, that the manufacturing arrangement (10) is set up to schedule the re-production of the rejected part immediately before or after a subsequent order, taking into account the raw materials used in the subsequent order compared to the raw materials used in the re-production.

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