Computer-supported manufacturing method, and manufacturing system
Patent Information
- Application Number
- EP2023785736
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2022-10-07
- Filing Date
- 2023-09-29
- Publication Date
- 2025-08-13
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 according to a planned production sequence using a machine tool. Furthermore, the invention relates to a manufacturing system for implementing the manufacturing method.
[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 laser cutting, a variety of factors 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 subsequently be remade to fully complete a production order.
[0006] Typically, defective or damaged workpieces are remanufactured by an operator, usually manually and at great expense. Remanufacturing individual workpieces often requires the use of unused workpiece blanks, which, however, cannot subsequently be fed into the regular production process. Remanufacturing these defective or damaged workpieces therefore results in considerable additional costs and material waste.
[0007] 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.
[0008] Object of the invention
[0009] The invention is based on the object of providing a method for operating a machining device that can avoid high manufacturing costs and high material waste caused by the remanufacturing of defective and / or damaged workpieces. Furthermore, the object is to provide a corresponding manufacturing system.
[0010] Description of the invention
[0011] 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 8. The subclaims represent preferred embodiments.
[0012] According to the invention, a computer-aided manufacturing process is provided.
[0013] The 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 rolled product, for example, a sheet metal coil or a fabric roll. The process involves the use of a machine tool, in particular a flatbed machine tool, with a processing device. The processing device can be designed, for example, as a cutting machine or punching machine.
[0014] 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 relate to workpiece groupings. The production plan can comprise workpieces and / or workpiece groupings from different production orders.
[0015] The production plan typically contains geometric production data for the workpieces to be manufactured, for example, one or more workpiece dimensions, in particular the workpiece thickness, a workpiece material, 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 can be dispensed with.
[0016] In a further method 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. For example, a laser cutting machine can begin cutting out workpieces to be manufactured from the workpiece blank according to the production plan. In a further method step, a defective workpiece is identified or recognized. A defective workpiece can be understood, for example, as a workpiece that was manufactured incorrectly by the processing device, in particular under production parameters that deviate from the production plan. Furthermore, a defective workpiece can arise from damage to the workpiece during the production of the workpiece and / or during the production of further workpieces. Damage can occur, for example, as a result of a collision between the processing device and the workpiece.
[0017] The defective workpiece can be identified or detected during production and / or in the finished state. Identifying the defective workpiece means detecting it through a workpiece inspection. Identification can be performed by an operator. Preferably, the defective workpiece is identified by a control device on the machine tool. Particularly preferably, identification occurs automatically through regular or permanent monitoring of the production of the workpieces in the machine tool. Detection of a defective workpiece can occur, for example, through deviations from production parameters, in particular machine parameters, during the production of the workpiece.Furthermore, for example, a defective workpiece can be detected by reporting a collision between the processing device and the workpiece and / or by visually comparing the workpiece with the target state of the workpiece according to the production plan. A target state of the workpiece can also refer, for example, to the workpiece dimensions, the workpiece shape, and / or the edge quality.
[0018] In a further method step, production information relating to the identified defective workpiece is read out by a job control system. For this purpose, the identified defective workpiece can first be reported to the job control system. A report can be made by entering the defective workpiece into the job control system. Preferably, the job control system is configured to exchange data with the control device designed to identify the defective workpiece, whereby an automatic report of the defective workpiece can be made. The job control system then reads out the production-relevant information relating to the defective workpiece, in particular a workpiece thickness, a workpiece shape, and a workpiece material. Typically, the job control system reads the production information from the production plan.From the manufacturing information, order control can derive manufacturing requirements for a workpiece blank to be used. The workpiece blank to be used is typically similar or identical to the workpiece blank from which the defective workpiece was manufactured.
[0019] In a further process step, the order control determines a workpiece blank suitable for reproducing the defective workpiece in a planned production process depending on the production information read out.
[0020] The planned production process refers to the subsequent production of workpieces according to the production plan, followed by the production of workpieces according to a further production plan. In other words, the production process provides for the planned further production of workpieces from additional workpiece blanks.
[0021] The production process may include the further production of workpieces from additional workpiece blanks by the processing device and / or the further production of workpieces from additional workpiece blanks by at least one additional machine tool with an additional processing device. In other words, the production process may include the production of workpieces in additional machine tools using additional processing devices.
[0022] The job control system is preferably designed and configured to manage the production process. The job control system is particularly configured to create, read, and / or modify production plans within the production process. The job control system can be configured as a central controller for managing production plans for various machine tools.
[0023] To determine the suitable workpiece blank, the order control system can first read the blank information underlying the production plans in the planned production process for the workpiece blanks to be used in the production of the workpieces. Typically, the order control system then compares the blank information with the production information of the workpiece to be reproduced. A workpiece blank can be determined as suitable if the workpiece blank meets the production requirements derived from the production information of the workpiece to be reproduced.
[0024] In a subsequent process step, the workpiece to be reproduced is placed on the suitable workpiece blank by the order control system. In other words, the order control system can modify the production plan for the workpiece blank determined to be suitable in such a way that the workpiece to be reproduced is manufactured by a processing device during the execution of the production plan.
[0025] According to the invention, a computer-aided manufacturing process is thus provided in which a defective workpiece is remanufactured, preferably automatically, by the order control system in the planned production process. Manual remanufacturing of the defective workpiece is thus eliminated. Furthermore, a workpiece blank intended for the production of workpieces can be used for remanufacturing. This can minimize material waste.
[0026] In a preferred embodiment of the computer-aided manufacturing process, the manufacturing information includes a production end time for the workpiece to be reproduced. In this case, a workpiece blank can be determined as suitable if the machining of the workpiece blank by the machining device in the production sequence takes place before the production end time. In other words, it can be checked whether reproducing the defective workpiece would lead to a delay in the delivery date. This allows measures to be initiated for more urgent reproduction of the workpiece, for example, by manual reproduction.
[0027] Order management is preferably configured to automatically execute measures for more urgent re-production. This can further increase the degree of autonomy of the manufacturing process.
[0028] Further preferred is an embodiment of the computer-aided manufacturing method in which the manufacturing information comprises at least one workpiece dimension. The workpiece blank can be determined as suitable by the order control if the workpiece to be reproduced can be arranged on the workpiece blank, in particular in a free space between planned workpieces to be manufactured. In other words, the order control is configured to determine free spaces in the production plans of the planned production process. By arranging the workpiece to be reproduced in a free space in the production plan, a higher workpiece density on the workpiece blank and thus particularly resource-efficient remanufacturing can be enabled.
[0029] In a preferred development of the computer-aided manufacturing process, planned workpieces to be manufactured are rearranged in order to arrange the workpiece to be reproduced on the workpiece blank. In other words, the production process is subjected to a plan optimization by the order control system, taking the workpiece to be reproduced into account. Plan optimization can, for example, result in a rearrangement of the workpieces to be manufactured with reduced spacing and / or by space-saving nesting of the workpieces with one another on the workpiece blank. A further development of the computer-aided manufacturing process is preferred in which planned workpieces to be manufactured are arranged on a workpiece blank following the workpiece blank in order to arrange the workpiece to be reproduced on the workpiece blank.In other words, it can be provided that the workpiece to be remanufactured is prioritized, for example, based on the production end time, by postponing subsequent production orders. This allows for more urgent remanufacturing of the workpiece. For example, the production end time can be met by prioritizing the workpiece to be remanufactured. Preferably, the prioritization of a workpiece to be remanufactured only occurs if the prioritization allows the subsequent workpieces to be manufactured up to their production end time.
[0030] In a preferred embodiment of the computer-aided manufacturing method, the workpiece to be reproduced, arranged on the suitable workpiece blank, is manufactured by the processing device. Preferably, the at least one reproduced workpiece is inspected for defect-free production according to the preceding explanations, in particular regarding the method step "Identifying the defective workpiece." If the reproduced workpiece is again identified as defective, the previously described method can be performed again. Furthermore, an operator can be notified, allowing detailed troubleshooting to be carried out.
[0031] 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.
[0032] 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 a plurality of processing devices. The processing devices are typically each assigned to a machine tool. The job control system can be configured to comprise one or more machine tools. Preferably, the job control system is configured as a separate unit of the manufacturing system. In any case, the job control system is configured to communicate with at least one, in particular with all, processing devices.
[0033] The manufacturing system is configured to perform the manufacturing process described above and below.
[0034] 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.
[0035] Detailed description of the invention and drawing
[0036] Fig. 1 shows a manufacturing method according to the invention for producing workpieces in a schematic representation;
[0037] Fig. 2 shows a manufacturing system with a processing device and a job control for carrying out an exemplary embodiment of the manufacturing method according to the invention according to Fig. 1 in a schematic representation.
[0038] Fig. 1 shows a computer-aided manufacturing method 10 according to the invention in a schematic representation. The manufacturing method 10 is designed to manufacture workpieces 12 (see Fig. 2) from a workpiece blank 14 (see Fig. 2) according to a production 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).
[0039] The manufacturing method 10 comprises the following method steps: a) manufacturing 22 of at least one workpiece 12 by the machine tool 18; b) identifying 24 a defective workpiece 26; c) reading 28 of manufacturing information relating to the identified defective workpiece 26 by a job control 30; d) determining 32 a workpiece blank 34 (see Fig. 2) suitable for reproducing the defective workpiece 26 in a planned manufacturing sequence 36 (see Fig. 2) as a function of the read manufacturing information by the job control 30; e) arranging 38 a workpiece 40 to be reproduced on the suitable workpiece blank 34 by the job control 30.
[0040] In a subsequent process step, the workpiece 38 to be reproduced can be manufactured by the processing device 20.
[0041] Fig. 2 shows a schematic representation of a manufacturing system 42.
[0042] The manufacturing system 42 comprises the machining device 20 and the job control 30. 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 42 has at least two, in particular several, machine tools 18, each with a machining device 20.
[0043] In the following, the manufacturing process 10 (see Fig. 1) is explained in more detail using the manufacturing system 42 shown.
[0044] According to method step 22 (see Fig. 1) "Manufacturing at least one workpiece," at least one workpiece 12 is manufactured by the machining device 20 of the machine tool 18 based on the production plan 16. The production plan 16 was typically transmitted to the machining device 20 by the order control 30 prior to the manufacturing process 22. As shown, several workpieces 12 were manufactured by the machining device 20 and are present as manufactured workpieces 44.
[0045] Furthermore, according to Fig. 2, several of the workpieces 12 to be manufactured are present as unfinished workpieces 46. In other words, the illustration in Fig. 2 shows a current state during the manufacturing of the workpieces 12.
[0046] According to a further method step 24 (see Fig. 1) "Identifying a defective workpiece," a defective workpiece 26 that is damaged and / or incorrectly manufactured by the processing device 20 is identified. The identification or recognition of the defective workpiece 26 can, as shown, take place during the manufacturing 22 of the workpieces 12. In particular, it can be provided that a defective workpiece 26 is recognized as such already during the manufacturing 22 of the defective workpiece 26.
[0047] For identification purposes, the manufacturing system 42, in particular the machine tool 18 and / or the job control system 30, may have control means (not shown in detail) that, for example, detect irregularities during the manufacturing 22 of the workpieces 12 on the processing device 20 and / or compare workpieces 44 manufactured by optical evaluation devices with a target state derivable from the production plan 16. In other words, the defective workpiece 26 can be assigned as such to a workpiece 12 actually to be manufactured in the production plan 16 and identified as defective based on deviations.
[0048] The information about the defective workpiece 26 and / or about the workpiece 12 actually to be manufactured can be reported to the job control 30, preferably to a comparison unit 50 of the job control 30.
[0049] In a further method step 28 (see Fig. 1) "Reading out production information," the order control 30, preferably the comparison unit 50, reads out the production information relating to the defective workpiece 26 or to the workpiece 12 actually to be manufactured. Typically, the order control 30 reads out the production information from the production plan 16 as shown.
[0050] According to a further method step 30 (see Fig. 1) "Determining a suitable workpiece blank", the order control 30 determines a workpiece blank 34 suitable for reproducing the defective workpiece 26 in a planned production process.
[0051] For this purpose, it can be provided that the order control 30, in particular the comparison unit 50 as shown, derives blank requirements from the read-out production information for the workpiece 40 to be reproduced. Typically, a suitable workpiece blank 34 must, for example, have the same material and the same blank thickness as the workpiece blank 14 actually intended for manufacturing the defective workpiece 26.
[0052] The production process may include one, or two, additional production plans 16a, 16b as shown. Production plans 16a, 16b are provided, for example, for manufacturing workpieces 12a, 12b from workpiece blanks 14a, 14b following the processing of production plan 16 by processing device 20. Production plans 16a, 16b are preferably managed by job control 30. In other words, production plans 16a, 16b can be modified by job control 30, in particular by comparison unit 50.
[0053] In the example shown, both production plan 16a and production plan 16b of production process 36 have clearances 52. According to the example, clearances 52 are sufficiently dimensioned to remanufacture the defective workpiece 26 either according to production plan 16a from workpiece blank 14a or according to production plan 16b from workpiece blank 14b. In other words, blank requirements regarding the dimensions of a clearance 50 required to remanufacture the defective workpiece 26 can be met.
[0054] The workpiece blank 14a may have a blank thickness that is, for example, less than or greater than the blank thickness of the workpiece blank 14. Alternatively or additionally, the workpiece blank 14a may have a different blank material compared to the original workpiece blank 14. In other words, the blank requirements regarding a blank thickness and / or a blank material may not be met.
[0055] In this case, the order control system 30 can provide for the blank requirements to be compared with the next workpiece blank 14b in the production process. For example, the workpiece blank 14b may meet all blank requirements. The workpiece blank 14b is then identified by the order control system 30 as a suitable workpiece blank 34.
[0056] According to a further method step 38 (see Fig. 1) "Arranging the workpiece to be reproduced on the workpiece blank," the workpiece 12 to be reproduced is arranged on the workpiece blank 14b. In other words, the production plan 16b is changed by the order control 30 so that it includes the remanufacturing of the defective workpiece 26 together with the production of the workpieces 12b.
[0057] Manufacturing process 10;
[0058] Workpiece 12, 12a, 12b;
[0059] Workpiece blank 14, 14a, 14b;
[0060] Production plan 16, 16a, 16b;
[0061] Machine tool 18;
[0062] processing device 20;
[0063] Process step 22 "Manufacturing a workpiece"
[0064] Process step 24 “Identifying a defective workpiece”;
[0065] Defective workpiece 26;
[0066] Process step 28 “Reading out production information”;
[0067] Order control 30;
[0068] Process step 32 “Determining a suitable workpiece blank”;
[0069] Suitable workpiece blank 34;
[0070] Production process 36;
[0071] Process step 38 "Arranging a workpiece to be reproduced on the suitable workpiece blank";
[0072] Workpiece to be reproduced 40;
[0073] Manufacturing system 42;
[0074] Manufactured workpieces 44;
[0075] Unfinished workpiece 46;
[0076] Comparison unit 50;
[0077] Open space 52.
Claims
Patent claims Computer-aided manufacturing method (10) for manufacturing workpieces (12, 12a, 12b) from a workpiece blank (14, 14a, 14b) according to a manufacturing plan (16, 16a, 16b) by a machine tool (18), in particular a flatbed machine tool, with a processing device (20), comprising the method steps: a) manufacturing (22) of at least one workpiece (12, 12a, 12b) by the machine tool (18); b) identifying (24) a defective workpiece (26); c) reading (28) manufacturing information about the identified defective workpiece (26) by a job control (30); d) determining (32) a workpiece blank (34) suitable for reproducing the defective workpiece (26) in a planned manufacturing process (36) depending on the read-out manufacturing information by the job control (30); e) Arranging (38) the workpiece (40) to be reproduced on the suitable workpiece blank (34) by the order control (30).Computer-aided manufacturing method (10) according to claim 1, wherein the manufacturing information includes a manufacturing end time for the workpiece (40) to be reproduced, wherein the workpiece blank (14, 14a, 14b) is determined to be suitable if the machining of the workpiece blank (14, 14a, 14b) by the machining device (20) in the manufacturing sequence (36) takes place before the manufacturing end time. Computer-aided manufacturing method (10) according to claim 1 or 2, wherein the manufacturing information includes a workpiece dimension, wherein the workpiece blank (14, 14a, 14b) is determined to be suitable if the workpiece (40) to be reproduced can be arranged on the workpiece blank (14, 14a, 14b), in particular in a free space (52) between planned workpieces (12, 12a, 12b) to be manufactured. Computer-aided manufacturing method (10) according to claim 3, wherein, in order to arrange the workpiece (40) to be reproduced on the workpiece blank (14, 14a, 14b), planned workpieces (12, 12a, 12b) to be manufactured are rearranged. Computer-aided manufacturing method (10) according to claim 4, wherein, in order to arrange the workpiece (40) to be reproduced on the workpiece blank (14, 14a, 14b), planned workpieces (12, 12a, 12b) to be manufactured are arranged on a workpiece blank (14, 14a, 14b) following the workpiece blank (14, 14a, 14b). Computer-aided manufacturing method (10) according to one of the preceding claims, wherein the workpiece (40) to be reproduced arranged on the suitable workpiece blank (34) is manufactured by the machining device (20). Computer-aided manufacturing method (10) according to one of the preceding claims, wherein the machine tool (18) is designed as a laser cutting machine.Manufacturing system (42) comprising at least one processing device (20) and the job control (30) configured to carry out the manufacturing method (10) according to one of the preceding claims.