Method for displaying handling assistance images and control device for press brakes

Abstract

As the bending process progresses with the press brake, the system displays the necessary images in a timely manner without requiring manual switching by the operator, enabling efficient bending. [Solution] When the NC device 10 detects that bending of the workpiece W has started with the press brake 100, it displays a handling image on the display device 30 showing how the operator of the press brake 100 is holding the workpiece W. When it detects that the workpiece W has been inserted into the press brake 100, it displays a workpiece image on the display device 30 superimposed on an image of the workpiece W and the abutment 42. When it detects that the workpiece W has been removed from the press brake 100, it displays a change support image on the display device 30 showing the procedure for changing how to hold the workpiece W from how to hold it in the current process to how to hold it in the next process.

Description

Technical Field

[0001] The present invention relates to a method for displaying a handling support image and a control device for a press brake.

Background Art

[0002] Patent Document 1 describes a method of forming a part by deforming a workpiece made of sheet metal with a bending machine. In the method of forming the part described in Patent Document 1, an image of the processing area is displayed on a display means, and an image serving as a work guide such as an arrow is superimposed and displayed on the image of the processing area.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the bending process performed by a press brake, the necessary information changes moment by moment in a short time. Therefore, the necessary information must be displayed to the operator in a timely manner as the bending process progresses. However, in the conventional method of forming a part described above, the machine side cannot recognize the progress of the bending process, so the operator has to manually switch the display screen to obtain the necessary information. Therefore, there is a problem that the operator cannot efficiently perform the bending process because they need to manually switch the display screen one by one.

Means for Solving the Problems

[0005] A first aspect of one or more embodiments is a method for displaying handling support images, in which, upon detection that bending of a workpiece has started with a press brake, a handling image showing how the operator of the press brake is holding the workpiece is displayed on the display device of the press brake; upon detection that the workpiece has been inserted into the press brake, a workpiece image showing the workpiece pressed against the abutment of the press brake is superimposed on an image taken of the abutment and the workpiece and displayed on the display device; and upon detection that the workpiece has been removed from the press brake, a change support image showing a procedure for changing from how the workpiece is held in the current process to how it is held in the next process is displayed on the display device.

[0006] A second aspect of one or more embodiments is a press brake control device that, upon detecting that bending of a workpiece has started with the press brake, displays a handling image on the press brake's display device showing how the operator of the press brake is holding the workpiece; upon detecting that the workpiece has been inserted into the press brake, displays a workpiece image showing the workpiece pressed against the abutment of the press brake, superimposed on an image of the abutment and the workpiece, on the display device; and upon detecting that the workpiece has been removed from the press brake, displays a change support image on the display device showing a procedure for changing from how the workpiece is held in the current process to how it is held in the next process. [Effects of the Invention]

[0007] According to one or more embodiments of the handling support image display method, as bending progresses with the press brake, the necessary images can be displayed in a timely manner without the operator having to manually switch them, enabling efficient bending. [Brief explanation of the drawing]

[0008] [Figure 1] Figure 1 is a perspective view showing the structure of a press brake according to one embodiment. [Figure 2] Figure 2 is a block diagram showing the configuration of an NC device according to one embodiment. [Figure 3] Figure 3 is a flowchart showing the processing procedure for displaying handling support images by an NC device according to one embodiment. [Figure 4] Figure 4 shows an example of a handling image displayed by an NC device according to one embodiment. [Figure 5] Figure 5 shows an example of a superimposed image displayed by an NC device according to one embodiment. [Figure 6] Figure 6 shows an example of a change support image displayed by an NC device according to one embodiment. [Modes for carrying out the invention]

[0009] [Structure of a press brake] The following describes a press brake that implements the handling support image display method according to this embodiment, with reference to the drawings. Figure 1 is a perspective view showing the structure of the press brake. As shown in Figure 1, the press brake 100 includes an NC (Numerical Control) device 10 that functions as a control device, a camera 20, a display device 30, and a processing program database 50.

[0010] The press brake 100 comprises 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 hydraulic cylinders 6L and 6R provided on the left and right sides. An upper die, which is a punch P, is mounted on the upper die holder 2, and a lower die, which is a die D, is mounted on the lower die holder 4.

[0011] On the underside of the lower table 3 is a machining area 40 where the workpiece W is machined by the press brake 100, and multiple abutments 42 are positioned to move left and right along the back gauge carriage 41. The abutments 42 are configured to move in the height direction and the front and back direction as well.

[0012] The operator places the sheet metal workpiece W on the die D. The stopper 42 moves to the processing position according to the processing program before bending the workpiece W, so the operator places the workpiece W on the die D by pressing the far end against the stopper 42.

[0013] An operating pendant 7 is attached to the left side of the press brake 100 via an arm. The operating pendant 7 is equipped with a display unit 71 and several operating buttons, including a start button 72. The operating pendant 7 is connected to the NC device 10. A foot switch 8 for raising and lowering the upper table 1 is also connected to the NC device 10.

[0014] The NC device 10 functions as a control device that controls the press brake 100 and performs control of the bending process of the workpiece W by the press brake 100. Specifically, when processing the workpiece W, the NC device 10 reads a processing program from the processing program database 50, and when the start button 72 is operated, it starts processing the workpiece W according to the processing program. First, the NC device 10 moves the stopper 42 according to the processing program, and in response to the operation of the foot switch 8, it controls the hydraulic cylinders 6L and 6R to lower the upper table 1 and perform the bending process of the workpiece W.

[0015] Furthermore, when the NC device 10 performs bending using the press brake 100, it executes control to display an image to the operator of the press brake 100 to assist in handling the workpiece W.

[0016] Specifically, when the NC device 10 detects that the bending process of the work W has started with the press brake 100, it displays a handling image indicating how the operator of the press brake 100 holds the work W on the display device 30. Next, when the NC device 10 detects that the work W has been inserted into the press brake 100, it superimposes a work image showing the work W pressed against the abutment 42 of the press brake 100 on the imaging image of the abutment 42 and displays it on the display device 30. Then, when the NC device 10 detects that the work W has been removed from the press brake 100, it displays a change support image showing the change procedure from the way of holding the work W in the current process to the way of holding the work W in the next process on the display device 30.

[0017] The camera 20 is installed on a connecting bar 51 that connects the side plate 5R and the side plate 5L, and is disposed on the back side of the upper table 1. The camera 20 images the processing area 40 including the abutment 42 and the work W from above, and outputs the captured image to the NC device 10. The processing area 40 is an area where the work W is processed by the press brake 100, and is an area including from the right end to the left end of the lower table 3.

[0018] The display device 30 is a tablet terminal that displays an image for assisting in the handling of the work W, and is installed on the upper table 1 of the press brake 100. Therefore, the display device 30 is installed at a position where the operator pressing the work W against the abutment 42 can visually recognize it.

[0019] The processing program database 50 stores the processing program and stores information necessary for controlling the bending process executed by the press brake 100. For example, information regarding the shape of the work W, position information for arranging the work W, information on the abutment 42 used in the bending process, coordinates for arranging the abutment 42, and the like are stored.

[0020] Further, the machining program records at least the position of the stopper 42, the insertion direction and position of the workpiece W, the position of the stopper 42 against which the workpiece W is pressed, and the shape of the workpiece W for each bending step.

[0021] [Configuration of NC device] FIG. 2 is a block diagram showing the configuration of the NC device 10. As shown in FIG. 2, the NC device 10 includes a machining control unit 12 and an image control unit 14. Further, the NC device 10 is connected to a foot switch 8, a start button 72, a machining program database 50, a camera 20, outputs a control signal to a press brake 100, and outputs an image to a display device 30.

[0022] The machining control unit 12 acquires a machining program from the machining program database 50 and controls the bending of the workpiece W according to the machining program when the bending of the workpiece W is started. Specifically, when the foot switch 8 is operated by an operator, the machining control unit 12 controls the hydraulic cylinders 6L and 6R according to the machining program to slide the upper table 1. Further, the machining control unit 12 controls the position of the stopper 42 according to the machining program.

[0023] The image control unit 14 generates an image to be displayed on the display device 30 and outputs and displays the generated image on the display device 30. Specifically, the image control unit 14 generates a handling image, a workpiece image, a superimposed image in which the workpiece image is superimposed on the captured image, and a change support image.

[0024] The handling image is an image showing how the operator of the press brake 100 holds the workpiece W. The workpiece image is an image showing the workpiece W pressed against the stopper 42 of the press brake 100. The change support image is an image showing the change procedure from the way of holding the workpiece W in the current process to the way of holding the workpiece W in the next process. The image control unit 14 wirelessly transmits these generated images to the display device 30 for display.

[0025] The NC device 10 is composed of a computer having 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. By executing a program stored in memory via the processor, the NC device 10 performs control to display images on the display device 30 that assist in handling the workpiece W.

[0026] [Display processing of handling support images] Next, the display process of the handling support image by the NC device 10 according to this embodiment will be described. Figure 3 is a flowchart showing the processing procedure for the display of the handling support image. As shown in Figure 3, in step S101, the machining control unit 12 and the image control unit 14 acquire and read the machining program from the machining program database 50.

[0027] In step S103, the processing control unit 12 determines whether or not bending of the workpiece W has started with the press brake 100. If the operator has started bending of the workpiece W by operating the start button 72, the stopper 42 is moved to the position of the first bending process and the process proceeds to step S105. If bending has not started, the unit continues to determine whether or not bending has started.

[0028] In step S105, when the image control unit 14 detects that bending of the workpiece W has started with the press brake 100, it displays a handling image on the display device 30. The handling image shows how the operator of the press brake 100 holds the workpiece W, and is an image showing how the workpiece W is held during the first bending process.

[0029] Figure 4 shows an example of a handling image. As shown in Figure 4, the handling image is a three-dimensional simulation image showing the workpiece W oriented in the direction to be inserted into the press brake 100 and the position where the worker is holding the workpiece W. In Figure 4, an image of a hand 31 is displayed at the position where the worker is holding the workpiece W, and an arrow 33 indicates the direction in which the workpiece W is inserted into the press brake 100.

[0030] Thus, when the start button 72 is operated, the image control unit 14 detects that the bending process of the workpiece W has started and displays a handling image on the display device 30. Therefore, the operator can easily recognize the correct way to hold the workpiece W by simply operating the start button 72, as the handling image is automatically displayed.

[0031] In step S107, the image control unit 14 determines whether or not the workpiece W has been inserted into the press brake 100. Specifically, the image control unit 14 acquires an image captured by the camera 20 and performs image analysis to determine whether or not the workpiece W has been inserted into the processing area 40 of the press brake 100.

[0032] However, even without using the image captured by the camera 20, it is possible to determine whether or not the workpiece W has been inserted into the press brake 100 by providing a sensor that detects objects, such as a distance measuring sensor, on the stopper 42. Furthermore, it is also possible to determine whether or not the workpiece W has been inserted into the press brake 100 by capturing images of the worker's movements and performing posture and behavior estimation using AI (artificial intelligence).

[0033] Then, if the workpiece W is inserted into the press brake 100, the process proceeds to step S109. If the workpiece W is not inserted into the press brake 100, the process continues to determine whether or not the workpiece W has been inserted into the press brake 100.

[0034] In step S109, when the image control unit 14 detects that the workpiece W has been inserted into the press brake 100, it superimposes the workpiece image onto the image captured of the abutment 42 and displays it on the display device 30. The workpiece image is an image showing the workpiece W pressed against the abutment 42 of the press brake 100. This workpiece image is superimposed onto the image captured by the camera 20 of the abutment 42 to generate a superimposed image.

[0035] Figure 5 shows an example of a superimposed image in which a workpiece image is superimposed on an captured image. As shown in Figure 5, the workpiece image 45 is an augmented reality (AR) image showing the shape of the workpiece W pressed against the stopper 42 and the positions 46a, 46b, and 46c of the stopper 42 against which the workpiece W is pressed. The captured image is an image of the processing area 40 including the stopper 42, captured from above by the camera 20.

[0036] When the image control unit 14 acquires an image from the camera 20, it superimposes the workpiece image 45 onto the image to generate a superimposed image, which is then displayed on the display device 30. This allows the operator to accurately position the workpiece W in the machining area 40 by inserting the workpiece W so that it overlaps with the workpiece image 45.

[0037] In this way, the image control unit 14 detects that the workpiece W has been inserted into the press brake 100 and displays the superimposed image on the display device 30. Therefore, the operator can simply insert the workpiece W without manually switching anything, and the superimposed image will be displayed automatically. By aligning the workpiece W with the workpiece image 45 and pressing it against the butt joint 42, the workpiece W can be positioned in the correct machining location.

[0038] In step S111, the processing control unit 12 determines whether or not bending has been performed. Specifically, the processing control unit 12 determines whether or not bending of the workpiece W has been performed by operating the foot switch 8 to drive the hydraulic cylinders 6L and 6R and lowering the upper table 1. If bending has been performed, the process proceeds to step S113; if bending has not been performed, the process continues to determine whether or not bending has been performed.

[0039] In step S113, the image control unit 14 determines whether or not the workpiece W has been removed from the press brake 100. Specifically, the image control unit 14 acquires the image captured by the camera 20 and performs image analysis to determine whether or not the workpiece W has been removed from the processing area 40 of the press brake 100.

[0040] However, similar to the insertion of the workpiece W, even without using the image from the camera 20, a sensor that detects objects, such as a distance measuring sensor, may be provided on the stopper 42, or AI may be used to estimate the worker's posture and actions based on their movements.

[0041] If it is determined that the workpiece W has been removed from the press brake 100, the process proceeds to step S115. If the workpiece W has not been removed from the press brake 100, the process continues to determine whether or not the workpiece W has been removed from the press brake 100.

[0042] In step S115, the processing control unit 12 determines whether the bending process is complete based on the processing program. Specifically, the processing control unit 12 determines that the bending process is complete if all bending processes recorded in the processing program have been completed, and determines that the bending process is not complete if there are any bending processes that have not been completed. If the bending process is not complete, the process proceeds to step S117, and if the bending process is complete, the display process of the handling support image according to this embodiment is terminated.

[0043] In step S117, the machining control unit 12 determines whether there is a change in how the workpiece is held in the current process and how it is held in the next process. If there is a change, the unit proceeds to step S119; otherwise, it returns to step S107.

[0044] In step S119, when the image control unit 14 detects that the workpiece W has been removed from the press brake 100, it displays a change support image on the display device 30. The change support image is an image that shows the procedure for changing from how to hold the workpiece W in the current process to how to hold the workpiece W in the next process.

[0045] Figure 6 shows an example of a change support image. As shown in Figure 6, the change support image is an animated image that shows the change in how the workpiece W is held from the current process to the next process. Along with an arrow 55 indicating the direction in which the workpiece W is rotated, the change in how the workpiece W is held from the current process to the next process is displayed as a video.

[0046] In Figure 6, first, an image of workpiece W1 showing how to hold it in the current process, and an image of a hand 56 showing the position of holding workpiece W1, are displayed for about 1 second, remaining still. Then, when the image of the hand 56 disappears, an arrow 55 indicating the direction to rotate workpiece W1 is displayed, and an animation of workpiece W1 rotating is played. The animation then displays workpiece W2 showing how to hold it in the next process, and an image of a hand 58 showing the position of holding workpiece W2, remaining still for about 2 seconds. Since workpiece W2 for the next process has been rotated 180° from workpiece W1 in the current process, the back side is visible on the top.

[0047] In this way, the image control unit 14 detects that the workpiece W has been removed from the press brake 100 and displays a change support image on the display device 30. Therefore, the operator does not need to manually switch anything; simply by removing the workpiece W, the change support image is automatically displayed, and by changing how they hold the workpiece W while looking at the change support image, they can easily change to the grip for the next process.

[0048] After this, the process returns to step S107, and the processes from step S107 to step S119 are repeatedly executed. Finally, when it is determined in step S115 that the bending process is complete, the display process of the handling support image according to this embodiment is terminated.

[0049] [Effects of the Embodiment] As described in detail above, when the NC device 10 according to this embodiment detects that bending of the workpiece W has started with the press brake 100, it displays a handling image on the display device 30. When the NC device 10 detects that the workpiece W has been inserted into the press brake 100, it displays the workpiece image superimposed on the captured image on the display device 30, and when it detects that the workpiece W has been removed from the press brake 100, it displays a change support image on the display device 30. As a result, as bending progresses with the press brake 100, the necessary images are displayed in a timely manner without the operator having to manually switch them, allowing for efficient bending.

[0050] In particular, in the NC device 10 according to this embodiment, once the operator operates the start button 72, all images are automatically displayed until the bending process is completed. Therefore, the operator does not need to manually switch the display screen each time, and the bending process can be performed efficiently.

[0051] Furthermore, in the NC device 10 according to this embodiment, the handling image shows the workpiece W oriented in the direction to be inserted into the press brake 100, and the position where the operator holds the workpiece W. As a result, the operator can easily recognize the correct way to hold the workpiece W by looking at the handling image.

[0052] Furthermore, in the NC device 10 according to this embodiment, the workpiece image 45 shows the shape of the workpiece W that is pressed against the stopper 42, and the position of the stopper 42 against which the workpiece W is pressed. As a result, the operator can accurately position the workpiece W in the machining area 40 by inserting the workpiece W so that it overlaps with the workpiece image 45.

[0053] Furthermore, in the NC device 10 according to this embodiment, the change support image displays a video showing the change in how the workpiece W is held from the current process to the next process, along with an arrow 55 indicating the direction in which the workpiece W should be rotated. This allows the operator to easily change how they hold the workpiece W for the next process by changing their grip while looking at the displayed change support image.

[0054] As described above, embodiments of the present invention have been presented, but the statements and drawings that constitute part of this disclosure should not be understood as limiting the invention. Various alternative embodiments, examples, and operational techniques will become apparent to those skilled in the art from this disclosure. [Explanation of Symbols]

[0055] 1 Upper table 2 Upper mold holder 3 Lower table 4. Lower mold holder 5L,5R side plate 6L, 6R Hydraulic Cylinders 7 Operation Pendant 8 Footswitches 10 NC device (control device) 12 Machining Control Unit 14 Image Control Unit 20 cameras 30 Display device Images of hands 31, 56, and 58 33, 55 Arrows 41 Back Gauge Carriage 42. Hitting the wall 45 work pixels 46a, 46b, 46c Position of the abutment 50 Processing Program Database 51 Connecting bar 72 Start button 100 Press Brake D P Punch W, W1, W2 Work

Claims

1. When the press brake detects that bending of the workpiece has begun, a handling image showing how the press brake operator is holding the workpiece is displayed on the press brake's display device. When it is detected that the workpiece has been inserted into the press brake, the display device superimposes an image of the workpiece being pressed against the abutment of the press brake onto an image of the abutment and the workpiece, and displays it on the display device. When it is detected that the workpiece has been removed from the press brake, the display device will display a change support image showing the procedure for changing how the workpiece is held in the current process to how it will be held in the next process. How to display handling assistance images.

2. The handling image shows the workpiece oriented in the direction to be inserted into the press brake, and the position in which the operator holds the workpiece. A method for displaying a handling support image according to claim 1.

3. The aforementioned workpiece image shows the shape of the workpiece pressed against the abutment and the position of the abutment against which the workpiece is pressed. A method for displaying a handling support image according to claim 1.

4. The aforementioned change support image displays a video showing the change in how the workpiece is held, from the current method of holding it to the next method of holding it, along with an arrow indicating the direction in which the workpiece should be rotated. A method for displaying a handling support image according to claim 1.

5. When the press brake detects that bending of the workpiece has begun, a handling image showing how the press brake operator is holding the workpiece is displayed on the press brake's display device. When it is detected that the workpiece has been inserted into the press brake, the display device superimposes an image of the workpiece being pressed against the abutment of the press brake onto an image of the abutment and the workpiece, and displays it on the display device. When it is detected that the workpiece has been removed from the press brake, the display device will display a change support image showing the procedure for changing how the workpiece is held in the current process to how it will be held in the next process. A control device for press brakes.

Images