Display method of safety confirmation image

Abstract

To improve safety of work by warning an operator before a press brake starts processing action.SOLUTION: In a display method of a safety confirmation image, an NC device 10 that controls a press brake 100 causes a processing region image to be displayed in a tablet terminal 30 installed in an upper table 1 of the press brake 100, the processing region image being obtained by imaging a processing region 40 in which the press brake 100 processes a workpiece W, and the control device causes a safety confirmation image prompting a worker who arranges the workpiece W in the processing region 40 to confirm safety to be displayed so as to be superimposed on the processing region image before the press brake 100 starts processing action.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a method for displaying a safety confirmation image. [Background technology]

[0002] Patent Document 1 describes a method in which a camera is placed above at least the rear side of the upper table of the press brake, and an image is superimposed on the image captured by the camera as a work guide showing the position or movement of the backgauge when it hits the work surface. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] International Publication No. 2020 / 041807 Summary of the Invention [Problem to be solved by the invention]

[0004] However, in the conventional press brakes described above, the worker's gaze is focused on the screen displaying images that serve as work guidance, which causes the worker to neglect to check for safety near him or her, thereby reducing work safety. [Means for solving the problem]

[0005] In a method of displaying a safety confirmation image according to one embodiment of the present invention, a control device that controls a press brake displays a processing area image, which is an image of a processing area in which a workpiece is processed by the press brake, on a display device installed on an upper table of the press brake, and the control device displays a safety confirmation image, which prompts a worker placing the workpiece in the processing area to make a safety check, superimposed on the processing area image before the press brake starts its processing operation.

[0006] According to a method for displaying a safety confirmation image according to one aspect of the present invention, a safety confirmation image for prompting a worker to make a safety confirmation before the press brake starts a processing operation is displayed superimposed on a processing area image. This makes it possible to call the worker's attention before the press brake starts a processing operation, thereby improving the safety of the work. Effect of the Invention

[0007] According to one aspect of the present invention, the safety of work can be improved by issuing a warning to the worker before the press brake starts the processing operation. [Brief description of the drawings]

[0008] [Figure 1] FIG. 1 is a perspective view showing a structure of a press brake according to one embodiment. [Diagram 2] FIG. 2 is a block diagram showing a configuration of a press brake according to one embodiment. [Diagram 3] FIG. 3 is a diagram illustrating an example of a bending preparation completion image displayed by the NC device according to an embodiment. [Figure 4] FIG. 4 is a diagram showing an example of a safety confirmation image displayed by the NC device according to an embodiment. [Diagram 5] FIG. 5 is a diagram showing an example of a safety confirmation image displayed by the NC device according to one embodiment. [Figure 6A] FIG. 6A is a flowchart showing a processing procedure for displaying a safety confirmation image by an NC device according to an embodiment. [Figure 6B] FIG. 6B is a flowchart showing a processing procedure for displaying a safety confirmation image by the NC device according to an embodiment. [Figure 7] FIG. 7 is a diagram showing an example of a measurement result image displayed by the NC device according to one embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] [Press brake] Hereinafter, a press brake that executes a method for displaying a safety confirmation image according to this embodiment will be described with reference to the drawings. Fig. 1 is a perspective view showing the structure of a press brake. As shown in Fig. 1, the press brake 100 is an example of a processing machine, and includes an NC (Numerical Control) device 10 that functions as a control device, a camera 20, a tablet terminal 30 that functions as a display device, and a processing program database 50.

[0010] In the method of displaying a safety confirmation image in this embodiment, the NC device 10 that controls the press brake 100 displays a processing area image, which is an image of the processing area 40 where the workpiece W is processed by the press brake 100, on a tablet terminal 30 installed on the upper table 1 of the press brake 100, and displays a safety confirmation image, which prompts the worker placing the workpiece W in the processing area 40 to make a safety check, superimposed on the processing area image before the press brake 100 starts the processing operation.

[0011] The press brake 100 includes an upper table 1, a lower table 3, and left and right side plates 5R and 5L. An upper die holder 2 is attached to the upper table 1, and a lower die holder 4 is attached to the lower table 3. The upper table 1 is configured to move up and down by table drive devices 6L and 6R provided on the left and right. A punch Tp, which is an upper die, is attached to the upper die holder 2, and a die Td, which is a lower die, is attached to the lower die holder 4. The table drive devices 6L and 6R are configured with a drive mechanism including a servo motor and a reducer, and a ball screw mechanism that converts the rotational motion of the output shaft of the drive mechanism into linear motion along the vertical direction. The table drive devices 6L and 6R may be hydraulic cylinders, etc.

[0012] Abutments 42a and 42b that move in the left-right direction along the backgauge carriage 41 are disposed on the rear surface side of the lower table 3. The abutments 42a and 42b are configured to move also in the height direction and the front-rear direction.

[0013] The worker places the workpiece W, which is the sheet metal to be processed, on the die Td in the processing area 40. Since the butts 42a and 42b move to positions corresponding to the die Td before bending the workpiece W, the worker places the back end of the workpiece W on the die Td so that it butts against the butts 42a and 42b.

[0014] An operation pendant 7 having a display unit 71 and an operation unit 72 including a plurality of operation buttons is attached via an arm 7a to the left side of the press brake 100. The operation pendant 7 is connected to an NC device 10. In addition, a foot switch 8 having a close foot switch 81 for lowering the upper table 1 and an open foot switch 82 for raising the upper table 1 is connected to the NC device 10. A bending angle detection sensor 9 is disposed on the lower table 3, and automatically detects the angle of the workpiece W bent by bending, and outputs the detected data to the NC device 10.

[0015] The NC device 10 functions as a control device that controls the press brake 100, and executes control to display a safety confirmation image that prompts the operator of the press brake 100 to make a safety confirmation on the tablet terminal 30. Specifically, the NC device 10 displays a machining area image obtained by capturing an image of the machining area 40 on the tablet terminal 30, and displays a safety confirmation image that prompts the operator to make a safety confirmation by superimposing it on the machining area image before the press brake 100 starts the machining operation.

[0016] The NC device 10 also controls the bending of the workpiece W by the press brake 100. Specifically, when machining the workpiece W, the NC device 10 reads a machining program from the machining program database 50, and when an instruction to start machining the workpiece W is given, starts machining the workpiece W according to the machining program. First, the NC device 10 moves the butts 42a, 42b according to the machining program, controls the table drive devices 6L and 6R in response to the operation of the foot switch 8, and lowers the upper table 1 to perform bending of the workpiece W.

[0017] The NC device 10 is configured by a computer having a memory, a processor such as a CPU (Central Processing Unit), and various interfaces. The memory and various interfaces are connected to the processor via a bus. The NC device 10 executes control to display a safety confirmation image on the tablet terminal 30 by executing a program stored in the memory by the processor.

[0018] The camera 20 is attached to a connecting bar 51 that connects the side plate 5R and the side plate 5L, and is disposed on the rear side of the upper table 1. The camera 20 captures an image of the machining area 40 from above, and outputs the captured machining area image to the NC device 10. The machining area 40 is an area where the workpiece W is machined by the press brake 100, and includes an area from the right end to the left end of the lower table 3. Therefore, in addition to the workpiece W, the lower die holder 4, the die Td, the butts 42a, 42b, etc. are captured in the machining area image.

[0019] It is preferable that the camera 20 is equipped with a fisheye lens so that it can capture images from the right end to the left end of the lower table 3. However, the camera 20 may be equipped with a wide-angle lens or an ultra-wide-angle lens instead of a fisheye lens, as long as it can capture images from the right end to the left end of the lower table 3.

[0020] The tablet terminal 30 functions as a display device that displays images to be presented to the worker, such as a machining area image and a safety confirmation image, and is installed on the upper table 1 of the press brake 100. In other words, the tablet terminal 30 is installed in a position where it can be seen by the worker who places the workpiece W in the machining area 40. Therefore, there is a risk that the worker's line of sight will be focused on the screen of the tablet terminal 30, but in this embodiment, the safety confirmation image is superimposed and displayed before the press brake 100 starts the machining operation, so that the safety of the work is not reduced.

[0021] When an operator works with the press brake 100, the operator stands in front of the press brake 100 so as to face the press brake 100. The operator's line of sight is obstructed by the upper table 1, punch Tp, lower table 3, die Td, etc., and therefore visibility of the machining area 40 behind the upper table 1 and lower table 3 is reduced. In the machining area 40, the punch Tp, die Td, butts 42a, 42b, butted workpiece W, etc. are arranged. By capturing an image of the machining area 40 from above and behind the upper table 1 with the camera 20, it is possible to improve the visibility of the machining area 40, which has low visibility for the operator.

[0022] In order to set the tablet terminal 30, the upper table 1 is formed with a mounting section 301 extending in the left-right direction. The tablet terminal 30 is detachably mounted on the upper table 1, and is configured so that the mounting position can be changed in the left-right direction of the upper table 1 along the mounting section 301. The mounting section 301 may be configured so that the tablet terminal 30 can be fitted into a recess, for example, or so that the tablet terminal 30 can be mounted to the mounting section 301 with a magnet. However, the display device does not have to be the tablet terminal 30, and a dedicated display may be installed, or a display area may be provided on the upper table 1 to project an image from a projector.

[0023] The processing program database 50 stores processing programs and also stores information necessary for controlling the bending process executed by the press brake 100. For example, information on the shape of the workpiece W, position information on where the workpiece W is placed, information on the butts 42a and 42b used in the bending process, coordinates for placing the butts 42a and 42b, etc. are stored.

[0024] [NC device and tablet terminal] Fig. 2 is a block diagram showing the configurations of the NC device 10 and the tablet terminal 30. As shown in Fig. 2, the NC device 10 includes a processing control unit 15, an additional image generating unit 16, an image control unit 17, a safety confirmation image generating unit 18, and a wireless communication unit 19. The tablet terminal 30 includes a wireless communication unit 31, an image display control unit 32, and a display unit 33.

[0025] The machining control unit 15 acquires a machining program from the machining program database 50, and when an instruction to start machining the workpiece W is given, controls the machining of the workpiece W according to the machining program. Specifically, when the foot switch 8 is operated by an operator, the machining control unit 15 controls the table driving devices 6L and 6R according to the machining program to slide the upper table 1. In addition, the machining control unit 15 controls the positions of the butts 42a and 42b according to the machining program.

[0026] The additional image generating unit 16 generates an additional image to be displayed by superimposing it on the machining area image. The additional image is, for example, an image showing the machining position of the workpiece W to be machined in the bending process. To generate the additional image, the additional image generating unit 16 uses information on the shape of the workpiece W, the position where the workpiece W is placed, the bending line of the workpiece W, and information on the butts 42a and 42b.

[0027] The image control unit 17 generates an image to be displayed on the tablet terminal 30 and controls the display of the generated image. The image control unit 17 generates a superimposed image by superimposing an additional image and a safety confirmation image on the processing area image. The image control unit 17 also acquires measurement result data from the bending angle detection sensor 9, and generates and displays a measurement result image that displays the measurement result of the bending process.

[0028] 3 is a diagram showing a bending preparation completion image, which is an example of a superimposed image in which an additional image is superimposed on a processing area image. As shown in FIG. 3, the image control unit 17 arranges two processing area images, an entire image 60 and an enlarged image 61, one above the other. The entire image 60 is a processing area image obtained by capturing an image of the entire processing area 40, and the enlarged image 61 is a processing area image obtained by enlarging an area in the entire image 60 where the workpiece W is placed. Then, the image control unit 17 superimposes an additional image 62 on each of the entire image 60 and the enlarged image 61 to generate a bending preparation completion image. The additional image 62 is a virtual image showing a virtual processing position of the workpiece W to be processed in the bending process, and the worker arranges the actual workpiece W so that it matches the additional image 62.

[0029] As shown in Fig. 3, the image control unit 17 displays two machining area images, an entire image 60 and an enlarged image 61, as well as an icon 63 and a screen selection tab 64 on the bending preparation completion image. The icon 63 is for calling the worker's attention, and four icons are displayed in Fig. 3. The screen selection tab 64 is a button for the worker to select a screen to be displayed on the tablet terminal 30, and since "butting monitor" has been selected in Fig. 3, an image of the machining area 40 is displayed.

[0030] The safety confirmation image generating unit 18 generates a safety confirmation image that prompts the worker to make a safety confirmation, and outputs the image to the image control unit 17. The safety confirmation image generating unit 18 may output a safety confirmation image that is stored in advance, or may generate a safety confirmation image by changing a message or background required for each bending process.

[0031] Fig. 4 is a diagram showing an example of a superimposed image in which a safety confirmation image is superimposed on the bending preparation completion image of Fig. 3. The safety confirmation image 65 shown in Fig. 4 is an image that is superimposed on the entire machining area image, displays a message urging the worker to make a safety confirmation, and has a background that hides the machining area image. As shown in Fig. 4, the safety confirmation image 65 is superimposed on the entire machining area image of both the entire image 60 and the enlarged image 61 shown in Fig. 3, and a message "Check at hand" and an icon are displayed in white letters on a black background so that the machining area image cannot be seen.

[0032] As described above, in the safety confirmation image 65 shown in Fig. 4, the image of the processing area cannot be seen, and therefore the worker must visually confirm the processing area. Therefore, safety confirmation is reliably performed, and the safety of the work can be improved. However, the background of the safety confirmation image 65 may have a transparency that allows the worker to recognize the movement of moving objects. For example, by providing a black background with a transparency of about 10%, the image of the processing area cannot be seen, but the worker can recognize the movement of moving objects such as the punch Tp.

[0033] Fig. 5 is a diagram showing an example of a superimposed image in which a safety confirmation image is superimposed on the bending preparation completion image of Fig. 3. The safety confirmation image 66 shown in Fig. 5 is an image that is superimposed on a part of the machining area image and displays a message urging the worker to confirm safety. As shown in Fig. 5, in the center between the whole image 60 and the enlarged image 61, the message "Please check the safety of your hands before bending" is displayed in white letters on a black background. In this way, the safety confirmation image 66 shown in Fig. 5 allows the worker to see the machining area image, so it is possible to call the worker's attention without reducing the operability of the worker.

[0034] 3 to 5 to a wireless communication unit 31 of a tablet terminal 30. The wireless communication unit 31 receives the superimposed image and outputs it to an image display control unit 32. The image display control unit 32 outputs the superimposed image to a display unit 33 and executes control to display the superimposed image on the display unit 33.

[0035] [Safety confirmation image display processing] Next, a display process of a safety confirmation image by the NC device 10 according to this embodiment will be described below. 6A and 6B are flowcharts showing the procedure of the display process of a safety confirmation image.

[0036] 6A and 6B, in step S1, when the processing of the NC device 10 is started, the machining control unit 15 judges whether or not a machining program has been loaded into the NC device 10. If the machining program has not been loaded into the NC device 10 (NO), the processing of step S1 is repeatedly executed, and if the machining program has been loaded into the NC device 10 (YES), the process proceeds to step S2.

[0037] In step S2, the additional image generating unit 16 extracts information such as the shape of the workpiece W, the position of the workpiece W, and the coordinates of the abutment from the machining program, and generates an additional image for the bending process.

[0038] In step S3, the image control unit 17 superimposes the additional image on the processing area image captured by the camera 20 to generate a bending preparation completion image, and transmits the generated bending preparation completion image to the tablet terminal 30 via the wireless communication unit 19 and displays it.

[0039] In step S4, the safety confirmation image generating unit 18 generates a safety confirmation image. The generated safety confirmation image may be the safety confirmation image shown in Fig. 4, or may be the safety confirmation image shown in Fig. 5 in consideration of the operability of the worker. The image control unit 17 superimposes the generated safety confirmation image on the bending preparation completion image, and displays the image on which the safety confirmation image shown in Fig. 4 or 5 is superimposed on the tablet terminal 30. If any trouble or malfunction occurs, the image control unit 17 generates an alarm image and transmits it to the tablet terminal 30 for display.

[0040] In step S5, the image control unit 17 determines whether a predetermined time, for example 4 seconds, has elapsed, and if the predetermined time has elapsed (YES), the image control unit 17 proceeds to step S6, and if the predetermined time has not elapsed (NO), the image control unit 17 proceeds to step S7.

[0041] In step S6, the image control unit 17 ends the superimposed display of the safety confirmation image, and the bending preparation completion image shown in Fig. 3 is displayed on the tablet terminal 30. If any trouble or malfunction occurs, the image control unit 17 generates an alarm image and transmits it to the tablet terminal 30 for display.

[0042] In step S7, the processing control unit 15 determines whether the close foot switch 81 has been operated and a processing instruction has been input, and if no processing instruction has been input (NO), the process returns to step S5, and if a processing instruction has been input (YES), the process proceeds to step S8.

[0043] In step S8, the safety confirmation image generating unit 18 generates a safety confirmation image, and the image control unit 17 superimposes the generated safety confirmation image on the bending preparation completion image and displays it on the tablet terminal 30. However, since the press brake 100 has already started the processing operation and there is no need to consider operability, the image on which the safety confirmation image of Fig. 4 is superimposed is displayed on the tablet terminal 30. If any trouble or malfunction occurs, the image control unit 17 generates an alarm image and transmits it to the tablet terminal 30 for display.

[0044] In step S9, the processing control unit 15 lowers the upper table 1 to perform bending processing on the workpiece W.

[0045] In step S10, the image control unit 17 determines whether or not measurement by the bending angle detection sensor 9 has started. If measurement has started (YES), the process proceeds to step S11, and if measurement has not started (NO), the process proceeds to step S12 0.5 seconds after the close foot switch 81 is turned off. Note that in the case of processing in which the angle of the workpiece W is not detected by the bending angle detection sensor 9, or in the case of a model that is not equipped with the bending angle detection sensor 9, the process of step S10 can be omitted.

[0046] In step S11, the image control unit 17 displays a measurement result image that displays the measurement result by the bending angle detection sensor 9. As shown in FIG. 7, the measurement result image displays a finished angle 75, a measured angle 76, and a springback 77. The finished angle 75 is the angle after pressure is released from the workpiece W, and if there are two bending angle detection sensors 9 on the left and right, two angles are displayed. The measured angle 76 is the angle in a state where pressure is applied to the workpiece W. The springback 77 is the angle at which the workpiece W returns when pressure is released. If any trouble or malfunction occurs during measurement, the image control unit 17 generates an alarm image and transmits it to the tablet terminal 30 for display.

[0047] In step S12, the processing control unit 15 judges whether the bending process has been completed, and if the bending process has not been completed (NO), the processing control unit 15 continues to judge whether the bending process has been completed. On the other hand, if the bending process has been completed (YES), the measurement by the bending angle detection sensor 9 is terminated, and the image control unit 17 displays the bending preparation completion image shown in FIG. 3, and the process proceeds to step S13.

[0048] In step S13, the processing control unit 15 determines whether there is a next bending process or not, and if there is a next bending process (YES), the process returns to step S2, and if there is no next bending process (NO), the process ends the display process of the safety confirmation image according to this embodiment. Note that, although this embodiment illustrates a case where the safety confirmation image is displayed before each bending process to enhance safety, in consideration of operability, the safety confirmation image may be displayed only before the first bending process immediately after the start of automatic operation.

[0049] [Effects of the embodiment] As described above in detail, in the method for displaying a safety confirmation image according to this embodiment, the NC device 10 displays a machining area image obtained by capturing an image of the machining area 40 on the tablet terminal 30, and displays a safety confirmation image that prompts the worker to perform a safety confirmation by superimposing it on the machining area image before the press brake 100 starts the machining operation. This makes it possible to alert the worker before the press brake 100 starts the machining operation, thereby improving the safety of the work.

[0050] In addition, in the display method of the safety confirmation image according to the present embodiment, the safety confirmation image is superimposed on the entire processing area image, displays a message urging the worker to make a safety confirmation, and has a background in which the processing area image is not visible. This requires the worker to visually confirm the processing area, so that the safety confirmation can be reliably performed and the safety of the work can be improved.

[0051] Furthermore, in the method for displaying a safety confirmation image according to the present embodiment, the background of the safety confirmation image has a transparency that allows the worker to recognize the movement of a moving object, thereby enabling the worker to recognize that a punch or the like is moving even while the safety confirmation image is being displayed, thereby improving the safety of the work.

[0052] In addition, in the method for displaying a safety confirmation image according to this embodiment, the NC device 10 ends the superimposed display of the safety confirmation image after a predetermined time has elapsed. This automatically ends the display of the safety confirmation image after the predetermined time has elapsed, so that the operator can be alerted and work safety can be improved without deteriorating the operability of the operator.

[0053] Furthermore, in the method for displaying a safety confirmation image according to this embodiment, the display device is a tablet terminal 30, which is detachably attached to the upper table 1. This makes it possible to display the safety confirmation image using a commonly used tablet terminal, eliminating the need to install a dedicated display and reducing costs.

[0054] As described above, the embodiment of the present invention has been described, but the description and drawings forming a part of this disclosure should not be understood as limiting this invention. From this disclosure, various alternative embodiments, examples, and operation techniques will be apparent to those skilled in the art. In particular, in this embodiment, the processing machine is a press brake, but even in processing machines other than press brakes, it is possible to display a safety confirmation image to alert the operator. Therefore, the present invention can be applied to processing machines other than press brakes. [Explanation of symbols]

[0055] 1 Upper table 2 Upper mold holder 3 Lower table 4 Lower die holder 5L,5R side plate 6L, 6R Table drive unit 7 Operation Pendant 8 Foot Switch 9 Bending angle detection sensor 10 NC unit (control unit) 15 Processing control section 16 Additional image generation section 17 Image control section 18 Safety confirmation image generation unit 19, 31 Wireless Communication Department 20 Camera 30 Tablet terminal (display device) 32 Image display control unit 33, 71 Display section 40 Processing area 41 Backgauge carriage 42a, 42b butt 50 Machining program database 51 Connecting bar 60 Full image 61 Enlarged image 62 additional images 63 Icons 64 Screen Selection Tab 65, 66 Safety confirmation images 72 Control section 75 Finishing angle 76 Measurement Angle 77 Springback 100 Press Brake Td die Tp Punch W work

Claims

1. A control device that controls the press brake displays a processing area image obtained by capturing an image of a processing area in which a workpiece is processed by the press brake on a display device installed on an upper table of the press brake, The control device displays a safety confirmation image, which prompts a worker who places the workpiece in the processing area to make a safety confirmation, on the processing area image before the press brake starts a processing operation. How to display safety confirmation images.

2. The safety confirmation image is superimposed over the entire processing area image, displays a message to the worker to prompt him / her to make a safety confirmation, and has a background against which the processing area image cannot be seen. The safety confirmation image display method according to claim 1 .

3. The background of the safety confirmation image has a transparency that allows the movement of a moving object to be recognized. The safety confirmation image display method according to claim 2 .

4. 4. The method for displaying a safety confirmation image according to claim 1, wherein the control device ends the superimposed display of the safety confirmation image after a predetermined time has elapsed.

5. The method for displaying a safety confirmation image according to any one of claims 1 to 3, wherein the display device is a tablet terminal and is detachably attached to the upper table.

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