Computer-supported manufacturing method, and manufacturing system
Patent Information
- Application Number
- EP2023783748
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2022-10-07
- Filing Date
- 2023-09-28
- Publication Date
- 2025-08-13
AI Technical Summary
Current computer-aided manufacturing processes face delays and material waste due to inefficient use of workpiece blanks, damage during production, and the need for manual re-manufacturing of faulty workpieces, leading to reduced automation and missed delivery deadlines.
A computer-aided manufacturing method and system that uses a processing device and order control to optimize workpiece arrangement and production planning, allowing for dynamic changes to the production plan during processing, enabling early start of production orders and efficient handling of faulty workpieces by automatically rearranging and reworking them on the same workpiece blank.
This approach reduces delays, increases workpiece blank utilization, minimizes material waste, and maintains high automation levels by allowing for real-time adjustments in production plans, ensuring timely completion of orders and reducing the need for reserve workpieces.
Smart Images
Figure 1.1
Abstract
Description
[0001] Computer-aided manufacturing process and manufacturing system
[0002] Background of the invention
[0003] The invention relates to a computer-aided manufacturing method for producing workpieces from a workpiece blank using a machine tool. The invention also relates to a manufacturing system with a processing device and a job control system.
[0004] Such processes are typically used in the processing of workpiece blanks in the form of sheet metal, which can be fed to the machine tool as sheet metal panels or coils. Such processes can also be used in the processing of materials. Cutting machines, particularly laser cutting machines, and / or punching machines are often used to process the workpiece blanks.
[0005] In order to achieve the highest possible efficiency of the machine tool while using the workpiece blanks as resource-efficiently as possible, the workpieces to be manufactured are arranged as densely as possible on a workpiece blank and the production plan is only released for processing by the machine tool when the workpiece blank is fully utilized or the workpiece density is high. This typically requires workpieces from several production orders to be combined in a single production plan. If a workpiece blank is not fully utilized by a production order, the processing of the production order is delayed or the processing takes place with a high level of material waste. In addition, a variety of influences in laser cutting can lead to a workpiece being damaged during production or being produced incorrectly by the machine tool.Such damaged or defective workpieces can be detected by the machine tool or the operator and must then be remanufactured in order to fully complete a production order.
[0006] Common procedures require that defective or damaged workpieces are either remanufactured manually by an operator, which is a laborious process, or are manufactured from a subsequent workpiece blank by the machine tool.
[0007] In all cases, remanufacturing these defective or damaged workpieces leads to significant delays, preventing production orders from being completed. To enable continued operation of the machine tool, additional storage space must be provided for the temporary storage of incomplete production orders.
[0008] Delays in processing production orders can also lead to missed delivery deadlines. In such cases, the machine tool's ongoing production process often has to be interrupted to produce defective or damaged workpieces on an additional workpiece blank, resulting in high material waste. This reduces the machine tool's level of automation and can significantly delay subsequent production orders.
[0009] To prevent delays, it is often planned that individual or all workpieces in a production order are manufactured twice or multiple times. In other words, reserve workpieces are produced to replace defective and / or damaged workpieces when needed. Unused reserve workpieces must then be disposed of. This leads to considerable material waste and a significantly longer production time and therefore does not represent an adequate solution to the problems described above.
[0010] Object of the invention
[0011] The invention is based on the object of providing a method for manufacturing workpieces that enables the processing of production orders with minimal delay while maintaining a high degree of autonomy and conserving resources. Furthermore, the object is to provide a corresponding manufacturing system.
[0012] Description of the invention
[0013] This object is achieved according to the invention by a computer-aided method according to claim 1. The object is further achieved by a manufacturing system according to claim 15. The subclaims relate to preferred embodiments.
[0014] According to the invention, a computer-aided manufacturing process is provided.
[0015] This manufacturing process is suitable for producing workpieces from a workpiece blank. A workpiece blank can be in the form of a sheet, for example, a metal sheet, and / or a raw material, for example, a sheet metal coil or a fabric roll.
[0016] The method involves using a machine tool, in particular a flatbed machine tool, with a machining device. The machining device can be configured, for example, as a cutting machine or punching machine.
[0017] The workpieces are manufactured from the workpiece blank by the machine tool according to a production plan. The production plan comprises at least one workpiece to be manufactured. Preferably, the production plan comprises several, particularly preferably a plurality of, workpieces to be manufactured. The production plan can comprise a workpiece grouping with several related workpieces, for example, a common assembly. In such cases, the process features described here and below can also refer to workpiece groupings. The production plan can comprise workpieces and / or workpiece groupings from different production orders.
[0018] The production plan typically contains geometric production data for the workpieces to be manufactured, for example, one or more workpiece dimensions, a workpiece contour, and / or a workpiece position on the workpiece blank. The production information is preferably encoded in a machine-readable format and contains all relevant information that enables the workpieces to be manufactured, particularly automatically. In other words, manual handling by an operator is eliminated.
[0019] The production plan typically has geometric dimensions that do not exceed the machining range of the machining device. The workpiece blank is preferably designed to fit the machining range of the machining device. For workpiece blanks that extend beyond the machining range of the machining device, for example, workpiece blanks in the form of raw material, the production plan can be limited to a workpiece blank section that corresponds to the machining range of the machining device.
[0020] In one step of the manufacturing process, the production plan is at least partially transmitted by a job control system. Typically, the production plan is transmitted in its entirety to the processing device. The job control system is typically designed to automatically create and / or transmit the production plan. When creating the production plan, based on underlying production orders with a discrete specification of the workpieces to be manufactured, the workpieces to be manufactured are preferably arranged or nested on the workpiece blank to be machined. The job control system can have computer algorithms, in particular self-learning ones, that optimize the arrangement or nesting of the workpieces on the workpiece blank. This can increase the utilization of the available workpiece blank.
[0021] In a further process step, at least one workpiece is manufactured from the workpiece blank according to the production plan. In other words, the machine tool begins manufacturing the workpieces. Typically, the workpiece blank has been fed into the machining area of the machining device, especially immediately beforehand.
[0022] In a further process step, the order control determines the manufacturing progress of the machining device during the production of the workpieces. In other words, the order control determines the workpieces already manufactured according to the production plan. The manufacturing progress can be determined, for example, at fixed intervals and / or at specific events during the execution of the production plan, such as the completion of a workpiece.
[0023] A further process step involves changing the production plan depending on the production progress during the production of the workpieces using order control. Order control can, for example, provide for a change in the arrangement of workpieces that are not yet manufactured and / or the reworking of workpieces that have already been manufactured.
[0024] According to the invention, a manufacturing method is thus provided that provides for a change in the production plan during the production of workpieces in the machine tool by means of job control. This allows, for example, the machine tool to begin processing a job before the workpiece blank has been completely filled with workpieces to be manufactured. Complete filling can be achieved during production by changing the production plan. Furthermore, a damaged or defective workpiece can be easily reproduced on the same workpiece blank. In all cases, delays in processing production orders can be reduced.
[0025] In a preferred embodiment of the computer-aided manufacturing process, the machine tool is designed as a laser cutting machine. The inventors have found the use of the manufacturing process in conjunction with a laser cutting machine to be particularly advantageous.
[0026] Further preferred is an embodiment of the computer-aided manufacturing method in which the manufacturing plan for the unfinished workpieces is changed.
[0027] In a preferred development of the computer-aided manufacturing process, the workpieces are manufactured by the processing device according to a production sequence specified in the production plan, with the order control changing the production sequence of the unfinished workpieces of the production order during the production of the workpieces. This can prevent delays in the completion of a production order, for example, by manufacturing an identical workpiece for a subsequent production order.
[0028] Further preferred is an embodiment of the computer-aided manufacturing method in which the order control supplements the production plan with at least one additional workpiece to be manufactured. Preferably, the order control determines, in particular automatically, a free space on the workpiece blank required for adding the additional workpiece to be manufactured in advance of the change to the production plan. The additional workpiece to be manufactured can, for example, be an additional workpiece to be manufactured that increases the utilization of the workpiece blank, for example, a subsequent production order. Preferred is a further development of the computer-aided manufacturing method comprising the method step
[0029] Identifying a manufactured defective and / or damaged workpiece, wherein the further complementary workpiece corresponds to the manufactured defective and / or damaged workpiece.
[0030] This allows the already manufactured defective and / or damaged workpiece to be reproduced without significant delay.
[0031] In a preferred embodiment of the computer-aided manufacturing process, the order control removes at least one unfinished workpiece from the production plan. Preferably, an unused reserve workpiece can be removed from the production plan. This allows a free space to be created on the workpiece blank for arranging a subsequent and / or supplementary workpiece.
[0032] Furthermore, an embodiment of the computer-aided manufacturing process is preferred in which the order control changes the arrangement of the not-yet-manufactured workpieces on the workpiece blank. Preferably, the change in the arrangement of the workpieces leads to a higher degree of workpiece loading on the workpiece blank. Particularly preferably, a change in the arrangement can be carried out by the order control in conjunction with the removal and / or addition of workpieces in the production plan. This can accelerate the processing of production orders.
[0033] Further preferred is an embodiment of the computer-aided manufacturing method in which the production plan is divided into at least two production sections. A production section is to be understood as a part of the production plan that is to be processed independently of the processing device. In other words, the production section contains all information relevant to the processing device in order to carry out the production of the workpieces according to the production section, independently of the rest of the production plan. The production sections can thus be transmitted separately from one another by the order control to the processing device. In other words, only part of the production plan is available to the processing device during the production of the workpieces. This makes it possible to limit changes to the production plan, for example, to the production sections that have not yet been transmitted to the processing device by the order control.The change of the production plan or a production section can be carried out particularly easily using order control without interfering with the production section to be processed by the processing device.
[0034] Preferably, the production progress can be determined by the order control through the production sections transmitted from the order control to the processing device.
[0035] In a preferred development of the computer-aided manufacturing process, each workpiece to be manufactured is manufactured in a separate production step. In other words, each individual workpiece can be transmitted to the processing device independently of the remaining production plan and manufactured by the processing device. In this case, the production plan can be transmitted through a synchronized and / or continuous transmission of the individual production steps to the processing device.
[0036] A particularly preferred development of the computer-aided manufacturing process is one in which the order control system transmits the production steps to the processing device depending on the production progress. This allows the transmission of the production steps to be dependent on the processing speed of the processing device.
[0037] A particularly preferred development of the computer-aided manufacturing process is one in which the order control system transmits a production section to the processing device when the previously transmitted production section has been processed by the processing device. This allows for the greatest possible flexibility when changing the production plan.
[0038] In a preferred embodiment of the computer-aided manufacturing process, the processing device can send a production progress report to the order control system during the execution of the production plan. This ensures that previously manufactured workpieces are recognized based on current information.
[0039] In a preferred embodiment, the computer-assisted
[0040] Manufacturing process a further processing device for the production of
[0041] Workpieces according to another production plan. In this case, it can be provided that the production plan of one of the processing devices is changed depending on a change in the production plan of the other processing device. This can, for example, make it possible to include workpieces to be reproduced in the production plan or on the
[0042] The workpiece blank of the other machining device can be picked up or arranged. In other words, the machining of workpieces to be manufactured can be carried out across all machines. This allows
[0043] Delays in the completion of production orders can be prevented particularly effectively.
[0044] The underlying problem is also solved by a manufacturing system. The manufacturing system comprises at least one processing device and the job control system. Preferably, the manufacturing system comprises at least two, in particular a plurality of, processing devices. Typically, each processing device is assigned to a machine tool.
[0045] The job control system can be a component of a machine tool. Furthermore, the job control system can be designed as a separate unit. In any case, the job control system is configured for communication or data exchange with at least one processing device.
[0046] The order control system is configured to execute the manufacturing process described above and below. In other words, the order control system is designed to create and modify production plans, particularly automatically, in the manner described above and below.
[0047] Changing production plans may, for example, and not exclusively, involve the addition of additional workpieces, the removal of workpieces, the arrangement of the workpieces, the production sequence, etc.
[0048] Further features and advantages of the invention will become apparent from the description, the claims, and the drawings. According to the invention, the above-mentioned and further-described features can be used individually or in combination in any convenient way. The embodiments shown and described are not intended to be exhaustive, but rather are exemplary in nature for describing the invention.
[0049] Detailed description of the invention and drawing
[0050] Fig. 1 shows a manufacturing method according to the invention for producing workpieces in a schematic representation;
[0051] Fig. 2 shows a manufacturing system with a processing device and a job control for carrying out an exemplary first embodiment of the manufacturing method according to the invention according to Fig. 1 in a schematic representation;
[0052] Fig. 3 shows the manufacturing system of Fig. 2 for implementing an exemplary second embodiment of the manufacturing method according to the invention. Fig. 1 shows a schematic representation of a computer-aided manufacturing method 10 according to the invention.
[0053] The manufacturing method 10 is designed to manufacture workpieces 12 (see Fig. 2) from a workpiece blank 14 (see Fig. 2) according to a manufacturing plan 16 (see Fig. 2) by a machine tool 18 (see Fig. 2), in particular a flatbed machine tool, with a processing device 20 (see Fig. 2).
[0054] The manufacturing method comprises the following method steps: a) At least partial transmission 22 of the manufacturing plan 16 by a job control 24 (see Fig. 2); b) Manufacturing 26 of at least one workpiece 12 from the workpiece blank 14 according to the manufacturing plan 16; c) Determination 28 of a manufacturing progress of the machining device 20 during the manufacture of the workpieces 12 by the job control 24; d) Modification 30 of the manufacturing plan 16 depending on the manufacturing progress during the manufacture of the workpieces 12 by the job control 24.
[0055] Fig. 2 shows a schematic representation of a manufacturing system 32.
[0056] The manufacturing system 32 comprises the machining device 20 and the job control 24. The machining device 20 is a component of the machine tool 18, which is designed to manufacture workpieces 12 from the workpiece blank 14 according to the production plan 16. For reasons of clarity, only two workpieces 12 are provided with a reference numeral. According to the embodiment shown, the job control 24 is designed as a separate unit and is configured for communication with the machining device 20. In a particular embodiment, it can be provided that the manufacturing system 32 has at least two, in particular several, machine tools 18, each with a machining device 20.
[0057] According to method step 22 "Transmitting the production plan," the order control system 24 transmits at least part of the production plan 16 to the processing device 20. The production plan 16 includes the production information required to manufacture the workpieces 12. Production information can be present, for example, in the form of a workpiece contour, a workpiece position, a production sequence, and / or a machine parameter of the workpiece 12 to be manufactured. As shown, the production plan 16 has been transmitted in its entirety to the processing device 20. In a special embodiment, it can be provided that the production plan 16 is divided into production sections, which are transmitted individually to the processing device 20. For example, one production section could relate to the production of the rectangular workpieces 12, while another production section could relate to the production of the round workpieces 12.In addition, each workpiece 12 may be contained in a separate manufacturing section.
[0058] In the further method step 26 "Manufacturing at least one workpiece," at least one workpiece 12 is manufactured by the processing device 20 according to the production plan 16. Several manufactured workpieces 34 are shown in Fig. 2.
[0059] In method step 28 "Determining a production progress," a production progress is determined during the processing of the production plan 16 by the order control 24. In other words, it can be determined which workpieces 12 have already been manufactured or are present as manufactured workpieces 34. Furthermore, it can be determined which workpieces 12 have not yet been manufactured or, as shown, are present as unfinished workpieces 36. By knowing the production progress, the production plan 16 can be changed by the order control 24 according to method step 30 "Changing the production plan." For example, it can be provided that a supplementary workpiece 38 is added to the production plan 16. This can be done by utilizing the available free space on the workpiece blank 16.Preferably, the order control 24 determines the free space available for this purpose on the workpiece blank 14, in particular automatically.
[0060] Furthermore, for example, it can be provided that during the production of the workpieces 12, one or more of the workpieces 12 are damaged and / or defectively manufactured. A damaged workpiece 40 is shown in Fig. 2. In this case, the manufacturing method 10 can provide that the supplementary workpiece 38 corresponds to the damaged and / or defectively manufactured workpiece 40. In other words, the damaged workpiece 40 can be reproduced on the same workpiece blank 14 without delay.
[0061] Fig. 3 shows the manufacturing method 32 from Fig. 2 for carrying out a further exemplary embodiment of the manufacturing method 10 from Fig. 1 for explanation.
[0062] According to the production process 16, at the beginning of the production of the workpieces 12, it is provided that a number of workpieces 12 as shown are to be produced from the workpiece blank 14 by the processing device 20 of the machine tool 18.
[0063] During the production of the workpieces 12, for example, two damaged workpieces 40 can be detected or identified by the processing device 20. The processing device 20 transmits information, for example the position and type, of the damaged workpieces 40 to the job control 24. The job control 24 determines the production progress of the processing device 20 during the execution of the production plan 16, wherein, for example, the manufactured workpieces 34 and the unfinished workpieces 36 are determined.
[0064] The order control system 24 can then make a change to the production plan 16 depending on the production progress. As shown, it can be provided that the order control system 24 creates a modified production plan 16a. As shown, the production plan 16a can include a change in the number of unfinished workpieces 36 in order to provide the free space required for arranging the additional workpieces 38 on the workpiece blank 14.
[0065] The modified production plan 16a is then transmitted to the processing device 20, which completes the processing of the workpiece blank 14 according to the modified production plan 16a.
[0066] The omitted workpiece 36 can, for example, be provided in a production plan 16 of a workpiece blank 14 to be subsequently machined.
[0067] It should be noted in general that, particularly in the case of production plans 16 which have a large number of workpieces 12 to be manufactured, a change to the production plan 16 can be made several times.
[0068] List of reference symbols
[0069] Manufacturing process 10;
[0070] Workpiece 12;
[0071] Workpiece blank 14;
[0072] Production plan 16, 16a;
[0073] Machine tool 18;
[0074] processing device 20;
[0075] Process step 22 “Transmitting the production plan”;
[0076] Order control 24;
[0077] Process step 26 "Manufacturing at least one workpiece"
[0078] Method step 28 “Determining a manufacturing progress of the processing device”;
[0079] Process step 30 “Changing the production plan”;
[0080] Manufacturing system 32; manufactured workpieces 34; unfinished workpieces 36; supplementary workpiece 38; damaged workpiece 40.
Claims
Patent claims Computer-aided manufacturing process (10) for manufacturing Workpieces (12) from a workpiece blank (14) according to a production plan (16, 16a) by a machine tool (18), in particular a flatbed machine tool, with a machining device (20), comprising the method steps: a) at least partial transmission (22) of the production plan (16, 16a) by an order control (24); b) manufacturing (26) of at least one workpiece (12) from the workpiece blank (14) according to the production plan (16, 16a) by the machining device (20); c) determining a production progress of the machining device (20) during the production of the workpieces (12) by the Order control (24); d) changing the production plan (16, 16a) depending on the production progress during the production of the workpieces (12) by the order control (24). Computer-aided manufacturing method (10) according to claim 1, wherein the machine tool (18) is designed as a laser cutting machine. Computer-aided manufacturing method (10) according to claim 1 or 2, wherein the production plan (16, 16a) is changed for unfinished workpieces (36). Computer-aided manufacturing method (10) according to claim 3, wherein the Workpieces (12) are manufactured by the processing device (20) according to a production sequence defined in the production plan (16, 16a); wherein the order control (24) Production sequence of the unfinished workpieces (36) of the Production plan (16, 16a) changes during the production of the workpieces (12). Computer-aided manufacturing method (10) according to one of the preceding claims, wherein the job control (24) supplements the manufacturing plan (16, 16a) with at least one further supplementary workpiece (38) to be manufactured. Computer-aided manufacturing method (10) according to claim 5, comprising the method step e) identifying a manufactured defective and / or damaged workpiece (40); wherein the further supplementary workpiece (38) to be manufactured corresponds to the manufactured defective and / or damaged workpiece (40). Computer-aided manufacturing method (10) according to one of the preceding claims, wherein the job control (24) removes at least one workpiece (12) to be manufactured from the manufacturing plan (16, 16a). Computer-aided manufacturing method (10) according to one of the preceding claims, wherein the job control (24) changes the arrangement of the still unmanufactured workpieces (36) on the workpiece blank (14).Computer-aided manufacturing method (10) according to one of the preceding claims, wherein the manufacturing plan (16, 16a) is divided into at least two manufacturing sections, wherein the manufacturing sections are transmitted separately from one another by the order control (24) to the processing device (20). Computer-aided manufacturing method (10) according to claim 9, wherein each workpiece (12) to be manufactured is stored in a separate Production section is manufactured. Computer-aided manufacturing method (10) according to claim 9 or 10, wherein the order control (24) transmits the production sections to the processing device (20) depending on the production progress. Computer-aided manufacturing method (10) according to claim 11, wherein the order control (24) transmits a production section to the Processing device (20) when the previously transmitted production section has been processed by the processing device (20). Computer-aided manufacturing method (10) according to one of the preceding claims, wherein the processing device (20) sends a production progress in the processing of the production plan (16, 16a) to the order control (24). Computer-aided manufacturing method (10) according to one of the preceding claims, comprising a further processing device (20) for producing workpieces (12) according to a further production plan (16, 16a), wherein the production plan (16, 16a) of one processing device (20) is changed depending on a change in the production plan (16, 16a) of the other processing device (20).Manufacturing system (32) comprising at least one processing device (20) and the job control (24) configured to carry out the manufacturing method (10) according to one of the preceding claims.