Diagnostic device for rebar processing machines
The diagnostic device for rebar processing machines accurately detects abnormalities by analyzing vibration data during stable operational periods, enhancing detection precision.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- TOYO KENSETABU KOKI
- Filing Date
- 2024-11-25
- Publication Date
- 2026-06-04
AI Technical Summary
Existing technologies lack the ability to accurately determine the presence or absence of abnormalities in steel bar processing machines.
A diagnostic device for rebar processing machines equipped with an actuator, power transmission mechanism, vibration sensor, and processor that acquires and analyzes vibration data during specific operational periods to detect abnormalities.
Enables accurate detection of abnormalities in rebar processing machines by analyzing vibration data during stable periods, excluding noise and improving detection accuracy.
Smart Images
Figure 2026091497000001_ABST
Abstract
Description
Technical Field
[0001] The technology of the present disclosure relates to a diagnostic device for a steel bar processing machine.
Background Art
[0002] Patent Document 1 describes an evaluation device including an AD conversion means for converting an analog signal of sound or vibration generated from mechanical equipment into a digital signal, and an analysis process is performed on the output of this AD conversion means to generate measured frequency spectrum data. Further, based on the presence or absence of peaks on the measured frequency spectrum data with respect to the primary value, secondary value, and fourth value of the frequency components generated due to abnormalities in the mechanical equipment, an arithmetic processing means for diagnosing the presence or absence of abnormalities in the mechanical equipment is provided.
[0003] Patent Document 2 describes an abnormality diagnosis system including a sensor unit attached to a device to be diagnosed, which periodically detects the acceleration of vibration and measures the time interval at which the acceleration is detected, a spectrum analysis means for performing spectrum analysis on the acceleration based on the detected value of the acceleration and the time interval detected by the sensor unit, and an abnormality detection means for detecting abnormalities in the device based on the spectrum for each frequency obtained by the spectrum analysis means.
Prior Art Documents
Patent Documents
[0004]
Patent Document 1
Patent Document 2
Summary of the Invention
Problems to be Solved by the Invention
[0005] The technology of the present disclosure aims to accurately determine the presence or absence of abnormalities in a steel bar processing machine.
Means for Solving the Problems
[0006] One aspect of the technology disclosed herein is as follows:
[0007] (1) A diagnostic device for a rebar processing machine having an actuator and a power transmission mechanism capable of transmitting the power of the actuator to a workpiece rebar, A vibration sensor for detecting vibrations of at least one of the actuator and the power transmission mechanism, Equipped with a processor, The above processor is During the operating period of the actuator and the power transmission mechanism, a portion of the first vibration data detected by the vibration sensor is acquired as second vibration data. A diagnostic device that determines whether or not there is an abnormality in the rebar processing machine based on the second vibration data described above.
[0008] (2) (1) The diagnostic device described above, The above processor is a diagnostic device that acquires vibration data detected by the vibration sensor as the second vibration data during the first timing when processing of the workpiece reinforcing bar is started and the second timing when processing of the workpiece reinforcing bar is completed, within the above operating period.
[0009] (3) (2) The diagnostic device described above, The above processor is a diagnostic device that acquires the second vibration data while the reinforcing bar to be processed is supplied to the above reinforcing bar processing machine and the reinforcing bar is being processed by the operation of the above actuator and the above power transmission mechanism.
[0010] (4) A diagnostic device described in any one of (1) to (3), The above processor is a diagnostic device that selects multiple data points from the above second vibration data at predetermined arbitrary time intervals and determines an abnormality in the rebar processing machine based on the above multiple data points.
[0011] (5) The diagnostic apparatus according to (4), In the diagnostic apparatus, for each of the plurality of data, the length of the period between the latest time and the oldest time among the measurement times is 0.5 seconds or more and 5 seconds or less.
Advantages of the Invention
[0012] According to the technology of the present disclosure, it is possible to accurately determine the presence or absence of abnormalities in the rebar processing machine.
Brief Description of the Drawings
[0013] [Figure 1] FIG. 1 is a schematic diagram showing a schematic configuration of a rebar bending machine 100 according to an embodiment of the technology of the present disclosure. [Figure 2] FIG. 2 is a plan schematic diagram showing the configuration of the rotary table 103. [Figure 3] FIG. 3 is a plan schematic diagram showing the configuration of the rotary table 103 during bending processing. [Figure 4] FIG. 4 is a diagram showing an example of first vibration data detected during the operation periods of the motor 101 and the speed reducer 102. [Figure 5] FIG. 5 is a diagram in which the vibration speeds converted from the first vibration data shown in FIG. 4 are plotted at intervals of 0.5 seconds. [Figure 6] FIG. 6 is a schematic diagram showing a schematic configuration of a rebar cutting machine 200. [Figure 7] FIG. 7 is a side view schematically showing a schematic configuration of the rebar cutting machine 200.
Embodiments for Carrying Out the Invention
[0014] FIG. 1 is a schematic diagram showing a schematic configuration of a reinforcing bar bending machine 100 according to an embodiment of the technology of the present disclosure. The reinforcing bar bending machine 100 is a device for bending a work piece such as a round bar or a deformed reinforcing bar T. The reinforcing bar bending machine 100 includes a motor 101 which is an example of an actuator, a speed reducer 102 which is an example of a power transmission mechanism, a disk-shaped rotating table 103 connected to the output shaft of the speed reducer 102, a vibration sensor 104 for detecting the vibration of the speed reducer 102, and a control device 105. The vibration sensor 104 and the control device 105 constitute a diagnostic device for the reinforcing bar bending machine 100.
[0015] The speed reducer 102 reduces the power of the motor 101 and transmits it to the rotating table 103 to rotate the rotating table 103.
[0016] The vibration sensor 104 is, for example, an acceleration sensor, and is fixed to the speed reducer 102 or a housing that houses the speed reducer 102 by adhesion or screwing. The vibration data (for example, acceleration) detected by the vibration sensor 104 is transmitted to the control device 105. While the power supply of the reinforcing bar bending machine 100 is on, the vibration sensor 104 periodically detects vibration, and the vibration data is transmitted to the control device 105.
[0017] FIG. 2 is a plan schematic diagram showing the configuration of the rotating table 103. The reinforcing bar bending machine 100 includes a flat reference surface portion 10 that constitutes a reference plane for specifying the bending direction during bending. An annular hole portion 10A is provided in the reference surface portion 10, and an annular rotating table 103 is provided inside the hole portion 10A so as to be rotatable in its circumferential direction (the direction indicated by the thick arrow in the figure). Hereinafter, the direction perpendicular to the reference surface portion 10 is defined as the vertical direction.
[0018] The reinforcing bar bending machine 100 includes a fulcrum member 11 and a reinforcing bar receiving portion 12 fixed to the upper surface of the reference surface portion 10 located inside the hole portion 10A, a force point member 21 fixed to the upper surface of the rotating table 103, and a support device 30 for supporting one end portion (the right end portion in the example of the figure) of the supplied work piece T.
[0019] The pivot member 11 is a member that constitutes the pivot point for the bending process, and is composed of, for example, a cylindrical roller in which the vertical direction and the axial direction coincide.
[0020] The rebar support portion 12 is positioned on the opposite side from the support member 11, with the supplied processed rebar T in between.
[0021] The force application member 21 is composed of, for example, a cylindrical roller whose vertical and axial directions coincide. The force application member 21 is positioned on one side (the rear side) of the workpiece T before bending, which is supplied to the rebar bending machine 100 and placed on the reference surface 10. In the state before the rebar bending machine 100 starts operation, as shown in Figure 2, the position of the force application member 21 in the circumferential direction of the rotary table 103 is the first position P1.
[0022] The control device 105 controls the entire rebar bending machine 100 and includes a processor such as a CPU (central processing unit) and memory. The control device 105 controls the motor 101 and uses its power to rotate the rotary table 103 to bend the rebar T to be processed. As the rotary table 103 rotates, the force point member 21 fixed to it rotates around the fulcrum member 11. The rotation direction of the rotary table 103 is defined as the first direction, which is clockwise in the plan view in Figure 1, and the second direction, which is counterclockwise, which is opposite to the first direction.
[0023] The operation of the rebar bending machine 100 will be explained with reference to Figures 2 and 3. First, as shown in Figure 2, the operator places the rebar to be processed T between the support member 11 and the rebar receiving part 12, and supports the right end of the rebar to be processed T with the support device 30. Next, when the operator initiates the bending process, the control device 105 controls the rotation table 103 to rotate in the first direction and bend the rebar to be processed T to the target bending angle. As the rotation table 103 rotates in the first direction, the force application member 21 comes into contact with the rebar to be processed T, and the bending force of the force application member 21 is applied to the rebar to be processed T, causing the rebar to bend in the first direction.
[0024] As shown in Figure 3, when the workpiece reinforcing bar T is bent to the target bending angle (90 degrees in the example shown), the control device 105 rotates the rotary table 103 in the second direction to return the force application member 21 to the first position P1. When the workpiece reinforcing bar T is bent to the target bending angle, the position of the force application member 21 in the circumferential direction of the rotary table 103 is the second position P2. In this way, during the operating period of the motor 101 and the reduction gear 102, the force application member 21 moves from the first position P1 to the second position P2, and after reaching the second position P2, moves back to the first position P1.
[0025] During the operation period of the motor 101 and the reduction gear 102, the vibration of the reduction gear 102 increases at the timing when the force application member 21 begins to move from the first position P1 to the second position P2, and at the timing when the force application member 21 begins to move back from the second position P2 towards the first position P1.
[0026] The control device 105 acquires second vibration data, which is a portion of the first vibration data detected by the vibration sensor 104 during this operating period, and determines whether or not there is an abnormality in the rebar bending machine 100 based on the acquired second vibration data. Specifically, the control device 105 acquires as second vibration data the vibration data detected by the vibration sensor 104 between the first timing when the processing of the rebar T to be processed begins (the timing when the force application member 21 starts moving from the first position P1 to the second position P2) and the second timing when the processing of the rebar T to be processed is completed (the timing when the force application member 21 starts moving back from the second position P2 towards the first position P1).
[0027] Figure 4 shows an example of first vibration data detected during the operating period of the motor 101 and the reduction gear 102. In the example in Figure 4, the first timing is 2 seconds and the second timing is 6.3 seconds, and vibration data between 2 seconds and 6.3 seconds is acquired as second vibration data. In the example in Figure 4, for example, the timing slightly before 2 seconds is the start timing of the operating period, and around 10 seconds is the end timing of the operating period.
[0028] The control device 105 performs a Fourier transform on the second vibration data (data showing the relationship between time and acceleration) and integrates the acceleration converted to the frequency domain into vibration velocity. The control device 105 then calculates the RMS value of the vibration velocity in the range of 10 Hz to 1000 Hz obtained in this way. Note that if a vibration sensor 104 that outputs vibration velocity as the detection result (vibration data) is used, processing such as the Fourier transform is unnecessary.
[0029] Figure 5 plots the vibration velocity converted from the first vibration data shown in Figure 4 at 0.5-second intervals. As shown in Figure 5, the vibration velocity increases during the period from 1.5 seconds to 2.5 seconds, which spans the first timing (=2 seconds). Also, the vibration velocity increases during the period from 5.5 seconds to 6.5 seconds, which spans the second timing (=6.3 seconds). On the other hand, the vibration velocity decreases between 3 seconds and 5.5 seconds.
[0030] The control device 105 further selects several vibration velocities from the vibration velocities converted from the second vibration data at predetermined arbitrary time intervals. For example, from the second vibration data converted to vibration velocity, the control device 105 selects six vibration velocities with a time interval of 0.5 seconds from data measured during a period when the vibration is particularly stable (in the example in Figure 5, the period between 3 seconds, which is after the first timing, and 5.5 seconds, which is before the second timing), assuming that no abnormalities occur in the motor 101 and the reduction gear 102.
[0031] In other words, the control device 105 obtains the vibration velocity at 3 seconds (1 second after the first timing), the vibration velocity at 3.5 seconds (1.5 seconds after the first timing), the vibration velocity at 4 seconds (2 seconds after the first timing), the vibration velocity at 4.5 seconds (2.5 seconds after the first timing), the vibration velocity at 5 seconds (3 seconds after the first timing), and the vibration velocity at 5.5 seconds (3.5 seconds after the first timing) from the second vibration data.
[0032] The duration of the period during which the vibration described above stabilizes is approximately 2 to 3 seconds if the bending angle of the processed reinforcing bar T is 90 degrees, and approximately 4 to 5 seconds if the bending angle of the processed reinforcing bar T is 180 degrees.
[0033] Therefore, by acquiring multiple vibration speeds selected between 3 and 5.5 seconds as measurement data and comparing this measurement data with a reference value, it becomes possible to determine whether or not there are any abnormalities in the reduction gear 102 of the rebar bending machine 100 (such as missing gear teeth, abnormal gear meshing, and loosening of housing fixing bolts). For example, if one or more vibration speeds between 3 and 5.5 seconds exceed the reference value, it can be determined that there is an abnormality in the reduction gear 102.
[0034] In this way, by determining anomalies based on vibrations detected between the first and second timings, data from timings where vibrations are large when no anomalies are present can be excluded, enabling highly accurate anomaly detection. In particular, determining anomalies based on vibrations during periods when the vibrations are stable can be performed with high accuracy.
[0035] The control device 105 may acquire the second vibration data when the force point member 21 is moved from the first position P1 to the second position P2 and then back to the first position P1 while the workpiece reinforcing bar T is not placed on the reference surface 10. However, it is preferable to acquire the second vibration data while the workpiece reinforcing bar T is being bent.
[0036] During bending, the motor 101 and the reducer 102 are under load, making it possible to detect abnormalities that cannot be detected under no-load conditions (when the force point member 21 is moved without supplying the workpiece reinforcing bar T). When detecting abnormalities while bending the workpiece reinforcing bar T, the vibration data detected by the vibration sensor 104 between the timing when the force point member 21 moves to the position where it first contacts the workpiece reinforcing bar T and the second timing may be acquired as second vibration data.
[0037] Furthermore, as shown in Figure 3, the control device 105 may determine whether or not there is an abnormality based on vibration data detected during the period from when the force point member 21 reaches the second position P2 until it returns from the second position P2 to the first position P1.
[0038] In the above description, the vibration sensor 104 is assumed to detect vibrations of the reduction gear 102, but this is not limited to this. The vibration sensor 104 may also detect vibrations of the motor 101. In this case, the vibration sensor 104 is fixed to the motor 101 or the housing that houses the motor 101. The rebar bending machine 100 may also have a configuration that includes a vibration sensor 104 for detecting vibrations of the motor 101 and a vibration sensor 104 for detecting vibrations of the reduction gear 102. By allowing the control device 105 to acquire vibrations of both the motor 101 and the reduction gear 102, abnormality can be determined with high accuracy. Furthermore, the configuration of the rebar bending machine is not limited to that shown in Figure 2, and the technology of this disclosure can be applied to various types.
[0039] In the above explanation, a rebar bending machine was shown as an example of a rebar processing machine, but the technology of this disclosure is also applicable to a rebar cutting machine.
[0040] Figure 6 is a schematic diagram showing the general configuration of the rebar cutting machine 200. The rebar cutting machine 200 comprises a motor 101, a reduction gear 102, a crank 106 connected to the reduction gear 102, a cutting blade 107 supported by the crank 106, a vibration sensor 104 that detects vibrations of at least one of the motor 101 and the reduction gear 102, and a control device 108 including a processor such as a CPU and memory. In the rebar cutting machine 200, when the control device 108 operates the motor 101, the power of the motor 101 is reduced by the reduction gear 102 and transmitted to the cutting blade 107 via the crank 106. As a result, the cutting blade 107 moves in a straight line. The vibration sensor 104 and the control device 108 constitute a diagnostic device for the rebar cutting machine 200.
[0041] Figure 7 is a schematic side view showing the general configuration of the rebar cutting machine 200. The rebar cutting machine 200 has a fixed blade 109 and a cutting blade 107 that is movable relative to the fixed blade 109, and the rebar T to be cut can be cut by the fixed blade 109 and the cutting blade 107. First, as shown in Figure 7, the operator places the rebar T to be processed between the fixed blade 109 and the cutting blade 107 and supports the right end of the rebar T. Next, when the operator starts the cutting process, the control device 108 rotates the motor 101. This moves the tip of the cutting blade 107 from the first position P1 to the second position P2. The second position P2 is the position where the rebar T can be cut. When the tip of the cutting blade 107 reaches the second position P2, the rebar T is cut. After the cutting of the rebar T is complete, the control device 108 controls the cutting blade 107 to return to the first position P1.
[0042] During the operating period of the motor 101 and the gearbox 102 in the rebar cutting machine 200, the vibration of the motor 101 and the gearbox 102 increases at the timing when the cutting blade 107 begins to move from the first position P1 to the second position P2, and at the timing when the cutting blade 107 begins to move back from the second position P2 towards the first position P1.
[0043] The control device 108 acquires second vibration data, which is a portion of the first vibration data detected by the vibration sensor 104 during this operating period, and determines whether or not there is an abnormality in the rebar cutting machine 200 based on the acquired second vibration data. Specifically, the control device 108 acquires as second vibration data the vibration data detected by the vibration sensor 104 between the first timing when the cutting of the rebar T to be processed begins (the timing when the cutting blade 107 starts moving from the first position P1 to the second position P2) and the second timing when the cutting of the rebar T to be processed is completed (the timing when the cutting blade 107 starts moving back from the second position P2 towards the first position P1).
[0044] The control device 108 further selects multiple vibration speeds from the vibration speeds converted from the second vibration data at predetermined arbitrary time intervals. For example, the control device 108 selects multiple vibration speeds from the second vibration data after conversion to vibration speed at predetermined arbitrary time intervals during a period when the vibration is particularly stable, provided that no abnormalities occur in the motor 101 and the reduction gear 102. By comparing these multiple vibration speeds with a reference value, it becomes possible to determine whether or not there are any abnormalities in the rebar cutting machine 200. In the case of the rebar cutting machine 200, the period during which the vibration is stable is approximately 0.5 to 2 seconds.
[0045] In this way, even in the rebar cutting machine 200, the presence or absence of abnormality in the rebar cutting machine 200 can be determined with high accuracy by using a portion of the vibration data detected by the vibration sensor 104. [Explanation of symbols]
[0046] P1 1st position P2 2nd position 10 Reference plane section 10A hole 11. Support Member 12 Reinforcement support section 21. Force Point Member 30 Support device 100 Rebar Bending Machine 101 Motor 102 Reducer 103 Rotating Table 104 Vibration Sensor 105,108 Control device 106 Crank 107 Cutting blade 109 Fixed blade 200 Rebar Cutting Machine
Claims
1. A diagnostic device for a rebar processing machine having an actuator and a power transmission mechanism capable of transmitting the power of the actuator to a rebar to be processed, A vibration sensor for detecting vibrations of at least one of the actuator and the power transmission mechanism, Equipped with a processor, The aforementioned processor, During the operating period of the actuator and the power transmission mechanism, a second vibration data is acquired, which is a portion of the first vibration data detected by the vibration sensor. A diagnostic device that determines whether or not there is an abnormality in the rebar processing machine based on the second vibration data.
2. A diagnostic device according to claim 1, The processor is a diagnostic device that, during the operating period, acquires vibration data detected by the vibration sensor as the second vibration data between the first timing when processing of the workpiece reinforcing bar begins and the second timing when processing of the workpiece reinforcing bar is completed.
3. A diagnostic device according to claim 2, The processor is a diagnostic device that acquires the second vibration data while the reinforcing bar to be processed is supplied to the reinforcing bar processing machine and the reinforcing bar is being processed by the operation of the actuator and the power transmission mechanism.
4. A diagnostic device according to any one of claims 1 to 3, The processor is a diagnostic device that selects multiple data points from the second vibration data at predetermined arbitrary time intervals and determines an abnormality in the rebar processing machine based on the multiple data points.
5. A diagnostic device according to claim 4, A diagnostic device in which the length of the period between the most recent and oldest measurement times of each of the aforementioned multiple data is 0.5 seconds or more and 5 seconds or less.