Press system and method for controlling press system

Abstract

To provide a press system and a control method of the same which can minimize a decrease in productivity even at the portion close to the end edge of a coil stock.SOLUTION: A loop table 300 includes operation changeover sensors 341, 342, and an abnormality sensor 330 which detect whether loop exists or not while a brake roll 250 sandwiches an end edge of a coil stock. A press system performs, even after the brake roll 250 sandwiches the end edge of the coil stock, a continuous running which continuously operates a feeder 400 and a press device 500 until the operation changeover sensors 341, 342, or the abnormality sensor 330 detects no loop. When the operation changeover sensors 341, 342, or the abnormality sensor 330 detects no loop, the press system stops the press device 500, and makes a feeder 400 feed the coil stock by a specified feed length at a feed rate which is slower than a feed rate of the continuous running.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a press system and a control method for a press system. [Background technology]

[0002] Conventionally, there is a tandem line press system in which devices arranged in the following order from upstream to downstream in the conveying direction of the coil material, namely, an uncoiler, a leveler, a loop table, a feeder, and a press device, work together to perform processing (see, for example, Patent Document 1). In such press systems, the setup process is often automated. For example, when the uncoiler runs out of coil material (workpiece), the devices arranged downstream of the uncoiler similarly automate the processing operation performed on the end of the coil material (hereinafter referred to as end processing operation).

[0003] If the device continues normal operation without detecting the end of the coil material, the end of the coil material may damage the devices on the tandem line or the coil material itself, especially in a tandem line press system. Therefore, after the transition to the end-processing operation, depending on the feed length and line speed, the feeder and press device may continue to operate continuously, or the feeder and press device may operate alternately. Specifically, when the feed length is less than a predetermined length and the line speed is less than a predetermined line speed, the feeder and press device perform the end-processing operation while maintaining continuous operation. On the other hand, when the feed length is equal to or greater than a predetermined length and the line speed is equal to or greater than a predetermined line speed, the feeder and press device operate alternately, and the end-processing operation is performed. This prevents the end of the coil material from damaging the devices on the tandem line or damaging the coil material itself. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2006-224165 Summary of the Invention [Problem to be solved by the invention]

[0005] However, in large tandem line press systems, processing is performed with a feed length equal to or greater than a predetermined feed length and a line speed equal to or greater than a predetermined line speed, and alternating operation is performed when the system transitions to the terminal processing operation. Therefore, with such press systems, there is a problem that productivity decreases when the system transitions to the terminal processing operation. Therefore, in tandem line press systems, it is desired to minimize the decrease in productivity as much as possible even when the coil material is near the terminal end.

[0006] The present invention has been made in consideration of the above circumstances, and an exemplary object of the present invention is to provide a press system and a control method for a press system that can prevent productivity from decreasing as much as possible even when the coil material is near the end. [Means for solving the problem]

[0007] In order to solve the above problems, the present invention has the following configuration. (1) A straightening device for straightening a curl of a coil material, the straightening device having an end detection means for detecting an end of the coil material, and a clamping means for clamping the end of the coil material when the end detection means detects the end of the coil material; a press device for processing the coil material; a feeding device that feeds the coil material of a predetermined feed length to the press device at a predetermined feed speed; a loop forming device that bends the coil material between the straightening device and the feeding device to form a loop, the loop forming device having: a discharge detection means that detects the timing when the clamping means that clamps the end of the coil material releases the coil material; and a support section that rises as the loop rises to support the loop; a control means for controlling the straightening device, the pressing device, the feeding device, and the loop forming device; A press system comprising: the loop forming device has a loop detection means for detecting the presence or absence of the loop while the clamping means is clamping the end of the coil material, The control means performs continuous operation by continuously operating the feeding device and the press device until the loop detection means detects that there is no loop, even after the clamping means has clamped the end of the coil material, and when the loop detection means detects that there is no loop, stops the press device and feeds the coil material by the specified feed length using the feeding device at a feed speed slower than the feed speed during the continuous operation.

[0008] Further objects and other features of the present invention will become apparent from the following description of preferred embodiments with reference to the accompanying drawings. [Effects of the Invention]

[0009] According to the present invention, it is possible to provide a press system and a method for controlling a press system that can prevent productivity from decreasing as much as possible even when the coil material is near the end. [Brief explanation of the drawings]

[0010] [Figure 1] FIG. 1 is a schematic front view showing the configuration of a press system according to an embodiment. [Figure 2] FIG. 2 is a block diagram of a press system according to an embodiment. [Figure 3] FIG. 3 is a schematic front view showing the configuration of the loop table according to the embodiment. [Figure 4] FIG. 4 is a schematic perspective view showing the configuration of a press device according to an embodiment. [Figure 5] FIG. 5 is a flowchart illustrating the termination process according to the embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0011] In the following description, operations including processing performed without detecting the end of the coil material are referred to as normal processing operations. In normal processing operations, productivity is prioritized, and the press machine continuously processes without stopping its operation. Continuous operation refers to a state in which the feeder supplies the coil material to the press machine in accordance with the operation of the press machine. On the other hand, operations including processing performed after the end of the coil material is detected are referred to as end processing operations, in which safety is prioritized over productivity. Furthermore, the height of the coil material being transported in the press system while processing is being performed in the press system (e.g., the height relative to the floor on which the press system is installed) is referred to as the processing height. The length of the coil material fed by the feeder in one feeding operation is referred to as the feed length (millimeters (mm)), and the speed at which the coil material is fed in one feeding operation is referred to as the feed rate. The feed length is the length of the coil material fed by the feeder into the press machine each time the press machine performs one processing (also referred to as one stroke).

[0012] Furthermore, the length that the coil material is fed in one minute, calculated by multiplying the rotation speed of the press machine (the number of strikes per minute) by the feed length, is called the line speed (meters per minute (m / min)). In a press system, the maximum feed length (hereinafter referred to as the maximum feed length) and the maximum line speed (hereinafter referred to as the maximum line speed) are included in the indexes that represent the performance of the press system.

[0013] [Embodiment] <Press system> FIG. 1 is a schematic front view showing the configuration of a press system 1 of this embodiment. FIG. 1 also shows the conveying direction of the coil material and the upstream and downstream directions. The press system 1 of this embodiment is equipped with an uncoiler 100, a leveler 200, a loop table 300, a feeder 400, and a press device 500. The uncoiler 100, the leveler 200, the loop table 300, and the feeder 400 operate in conjunction with the processing operation of the press device 500. The press system 1 is installed on a floor surface 10. The loop table 300 is installed in a pit 305 provided below the floor surface 10.

[0014] 2 is a block diagram of the press system 1 of this embodiment. In the following explanation, the configuration and function of each device will be explained with reference to FIGS.

[0015] <Uncoiler> The uncoiler 100, which is a holding device that holds the coil material 120, has a mandrel 110, a control unit 130, and a drive unit 140. The mandrel 110 holds the coil material 120, which is the object to be processed by the press device 500. For example, the inner diameter of the coiled coil material 120 is held by the mandrel 110. The control unit 130 rotates the mandrel 110 using the drive unit 140 in conjunction with the processing operation by the press device 500, thereby unwinding the coil material 120.

[0016] The uncoiler 100 supplies the coil material 120 to the leveler 200 at a constant speed until the coil material 120 runs out. In other words, the uncoiler 100 supplies the coil material 120 at a speed that corresponds to the operation of the feeder 400 and the press device 500, but unlike the feeder 400, which operates by repeatedly starting and stopping, the uncoiler 100 operates continuously.

[0017] <Leveler> The leveler 200 functions as a straightening device that straightens out any curls or other imperfections on the coil material 120 held by the uncoiler 100. The leveler 200 supplies the coil material 120 to the loop table 300 at a constant speed until it transitions to the terminal processing operation described below. In other words, the leveler 200 transports the coil material 120 at a speed that corresponds to the operation of the feeder 400 and the press device 500, but unlike the feeder 400, the leveler 200 does not repeatedly start and stop, but operates continuously.

[0018] The leveler 200 has a leveler entrance sensor 210, an entrance roll 220, a plurality of work rolls 230, a brake roll entrance sensor 240, a brake roll 250, a control unit 260, a memory unit 270, a cylinder 280, and a motor 290. In Fig. 1, each sensor is represented by a black inverted triangle, and this will also be the case in the devices described below.

[0019] The leveler entrance sensor 210 has, for example, a light-emitting unit (not shown) that emits light and a light-receiving unit (not shown) that receives the light emitted by the light-emitting unit. When the coil material 120 is located at the position of the leveler entrance sensor 210, the light emitted from the light-emitting unit is blocked by the coil material 120, and the leveler entrance sensor 210 outputs, for example, a low-level signal. On the other hand, when the end of the coil material 120 passes the position of the leveler entrance sensor 210, the light emitted from the light-emitting unit is received by the light-receiving unit (hereinafter also referred to as light transmission), and the leveler entrance sensor 210 outputs, for example, a high-level signal. However, from the perspective of considering safety, if the light-blocking state is on the safe side or in a steady state, a high-level signal may be output at that time, and if it is not safe or in a steady state, a low-level signal may be output.

[0020] The control unit 260 can determine whether the end of the coil material 120 has passed the position of the leveler entrance sensor 210 by monitoring the level of the signal output from the leveler entrance sensor 210. Specifically, the control unit 260 determines that the end of the coil material 120 has passed based on the change in the signal output from the leveler entrance sensor 210 from low level to high level. Hereinafter, the fact that the end of the coil material 120 has passed at the leveler entrance sensor 210 will be expressed as "detecting the end," and the same applies to other sensors. Note that the leveler entrance sensor 210 may be any sensor that can detect the end of the coil material 120, and the logic of the output signal may be reversed, and the means for notifying the control unit 260 may be other forms. Hereinafter, the fact that the control unit 260 has determined that the end of the coil material 120 has passed based on the detection result of the leveler entrance sensor 210 will also be expressed as "the leveler entrance sensor 210 has detected the end of the coil material 120."

[0021] The entrance rolls 220 are rolls for receiving the coil material 120 unwound by the uncoiler 100 into the leveler 200 and transporting it to the work rolls 230. The entrance rolls 220 are in a closed state to clamp the coil material 120, and in an open state to release the clamped state of the coil material 120 and release the coil material 120.

[0022] In a closed state, the work rolls 230 straighten out any curls or other imperfections in the coil material 120. The multiple work rolls 230 are arranged, for example, in a staggered arrangement with alternating steps, i.e., in a staggered configuration, and by clamping and transporting the coil material 120 unwound by the uncoiler 100, the work rolls gradually straighten out any curls or other imperfections in the coil material 120 from the upstream side to the downstream side in the transport direction of the coil material 120.

[0023] The brake roll entrance sensor 240 detects the presence or absence of the coil material 120, thereby functioning as an end detection means for detecting the end of the coil material 120. The configuration of the brake roll entrance sensor 240 can be the same as that of the leveler entrance sensor 210, and therefore a description thereof will be omitted.

[0024] The brake rolls 250 are in a closed state to clamp the coil material 120 and in an open state to release the coil material 120. When the brake roll entrance sensor 240 detects the end of the coil material 120, the brake rolls 250 are in a closed state and function as clamping means for clamping the coil material 120. The brake rolls 250 are in an open state while normal processing operations are being performed. Note that when the brake rolls 250 are in an open state, the brake rolls 250 may be rotated by the motor 290, or may have a transmission means such as a clutch so that the drive of the motor 290 is not transmitted by the transmission means, i.e., the brake rolls 250 may be stopped from rotating. When the end of the coil material 120 is detected by the leveler entrance sensor 210 and the end processing operation is started, the brake rolls 250 are transitioned from an open state to a closed state by the cylinder 280.

[0025] When the brake roll entrance sensor 240 detects the end of the coil material 120, the brake rolls 250 are stopped from rotating by stopping the drive by the motor 290, and maintain a closed state in which they clamp the end of the coil material 120. This state is hereafter referred to as the state in which the leveler 200 is stopped.

[0026] A cylinder 280 switches the entrance roll 220 and the brake roll 250 between a closed state and an open state. A motor 290 drives the rotation of the entrance roll 220, the work roll 230, and the brake roll 250. Note that the cylinder 280 need only be of a reciprocating type, and a spring, for example, can also be used.

[0027] The control unit 260 controls the cylinder 280 and the motor 290 in conjunction with the operation of other devices in the press system 1, thereby correcting any curling or other irregularities in the coil material 120 and sending (also referred to as supplying or transporting) the coil material 120 to the loop table 300. Note that the control unit 260 controls the rotation of the entrance roll 220, work roll 230, and brake roll 250 by a known method using detection means (not shown), such as an encoder. Similarly, the control unit 260 also controls the switching between the open state and the closed state of the entrance roll 220 and the brake roll 250 by a known method.

[0028] The control unit 260 controls the leveler 200 in conjunction with other devices of the press system 1 in accordance with various programs stored in the memory unit 270. The memory unit 270 stores, for example, the speed at which the coil material 120 is transported, and the control unit 260 transports the coil material 120 in accordance with the speed of the feeder 400 and the press device 500. The leveler 200 may also have a display unit and an input unit.

[0029] <Loop table> FIG. 3 is a schematic front view showing the configuration of the loop table 300. The loop table 300 is provided to absorb the difference in the speed at which the coil material 120 is supplied (hereinafter referred to as the speed difference) between the leveler 200, which supplies the coil material 120 at a constant speed, and the feeder 400, which repeatedly starts and stops in synchronization with the operation of the press device 500. Specifically, the loop table 300 bends the coil material 120 downward to form a loop-shaped portion (hereinafter simply referred to as a loop), providing the coil material 120 with a buffer during the conveyance process. This allows the loop table 300 to absorb the difference in the conveyance speed of the coil material 120 between the supply speed at the inlet side (leveler 200 side) of the loop table 300 and the discharge speed at the outlet side (feeder 400 side) of the loop table 300. The length of the loop formed within the pit 305 is also referred to as the loop amount. A long loop length is expressed as a large loop amount, and a short loop length is expressed as a small loop amount. 1, a small loop amount is indicated by a solid line, and a large loop amount is indicated by a dashed line. The loop table 300 functions as a loop forming device that bends the coil material 120 between the leveler 200 and the feeder 400 to form a loop.

[0030] (Loop amount) Hereinafter, the speed at which the leveler 200 supplies the coil material 120 is referred to as the supply speed of the leveler 200. Also, the speed at which the feeder 400 supplies the coil material 120 to the press device 500 is referred to as the consumption speed of the feeder 400. If the consumption speed of the feeder 400 is faster than the supply speed of the leveler 200, the loop amount becomes smaller and the lowest position of the loop in the pit 305 (hereinafter referred to as the lowest point) becomes higher. On the other hand, if the supply speed of the leveler 200 is faster than the consumption speed of the feeder 400, the loop amount becomes larger and the lowest point of the loop in the pit 305 becomes lower. Since the feeder 400 operates in synchronization with the operation of the press device 500, even if the consumption speed of the feeder 400 exceeds the supply speed of the leveler 200, the consumption speed of the feeder 400 is zero during the processing operation of the press device 500. Therefore, as long as the supply speed of the leveler 200 matches the average consumption speed of the feeder 400, taking into account the time when the consumption speed of the feeder 400 is zero, the loop amount will not become extremely large or small.

[0031] Between the leveler 200 and the feeder 400, a pit 305 of a predetermined depth is provided extending downward from the floor surface 10, and the loop table 300 is provided within and above the pit 305. Here, for example, in a large-scale press system 1 having a length (total length) of approximately 25 m from the uncoiler 100 to the press device 500, the maximum feed length is assumed to be 1000 mm to 2500 mm, and the maximum line speed is assumed to be 50 m / min to 80 m / min. In such a large-scale press system 1, the predetermined depth of the pit 305 is, for example, 5 m, and the height from the floor surface 10 to the processing height is, for example, 2 m to 3 m. Here, the coil material 120 used in such a press system 1 has, for example, a width (length in the direction perpendicular to the conveying direction) of 2 m and a thickness of 0.6 mm to 9 mm. Note that these numerical values ​​may be determined depending on the scale of the press system 1, the type of processing (in other words, the type of mold attached to the press device 500), etc. The processing height is shown by the dashed line in Figure 3.

[0032] The loop table 300 has a table 310, a contact sensor 312, an encoder 315, loop sensors 321, 322, 323, an abnormality sensor 330, an operation switching sensor 341, an operation switching sensor 342, and a discharge sensor 350. The loop table 300 further has a control unit 360, a memory unit 370, and a motor 380. The conveying direction, upstream, downstream, and up and down directions are also shown in Fig. 3.

[0033] Table 310 supports the loop of coil material 120 formed in pit 305. Table 310 functions as a support section that rises as the loop rises and supports the loop. Table 310 is provided with contact sensor 312. Contact sensor 312 is used by control unit 360 to determine whether or not the loop of coil material 120 is in contact with table 310. Contact sensor 312 may be, for example, a piezoelectric sensor, a conductive sensor, or any other sensor that can detect when the loop has come into contact with table 310.

[0034] Table 310 can be lowered, for example, to the position of table 310L shown by the two-dot chain line in FIG. 3. At the position of table 310L, table 310 supports coil material 120 that has reached the maximum loop amount that can be formed by loop table 300. Note that table 310L may be movable to a position lower than this position. Table 310 can also be raised to the position of table 310H, which is similarly shown by the two-dot chain line. At the position of table 310H, table 310 can safely receive the dispensed coil material 120, which will be described later. Note that table 310H may be movable to a position higher than this position.

[0035] Table 310A, indicated by a dashed line, shows a state in which the upper surface of table 310 is lower than discharge sensor 350 and is at a height h1 above floor surface 10; hereinafter, h1 is referred to as the material dischargeable height. Here, when leveler 200 transitions to the terminal processing operation and further releases the terminal end, brake roll 250 changes from a closed state to an open state, releasing the terminal end of coil material 120, and coil material 120 falls onto table 310. Material dischargeable height h1 is set to a height that will not cause scratches or the like on the dropped coil material 120. For example, in this embodiment, material dischargeable height h1 is set to a position slightly higher than floor surface 10. The fixed height h2 indicated by the dashed line will be described later.

[0036] The encoder 315 detects the height of the table 310 and notifies the control unit 360 of the height information of the table 310. For example, the control unit 360 determines that the table 310 has reached the material dischargeable height h1 based on the detection result of the encoder 315, and notifies the control unit 260 of the leveler 200. The same applies to the fixed height h2.

[0037] The loop sensors 321, 322, 323, the abnormality sensor 330, the operation switching sensor 341, the operation switching sensor 342, and the discharge sensor 350 may all have the same configuration as the leveler inlet sensor 210 described above, and therefore a description of their configurations will be omitted. These sensors each output a signal to the control unit 360 with different logic depending on whether a loop is present or absent. In the following description, "a loop has been detected" refers to a state in which a loop is present at the position (height) of each sensor. On the other hand, "no loop has been detected" refers to a state in which the lowest point of the loop has moved from below to above at the position (height) of each sensor, and no loop is present at that sensor's position; in other words, the height of the lowest point of the loop has been detected. For this reason, hereinafter, the state in which these sensors no longer detect a loop may be expressed as "the height of the loop has been detected."

[0038] Loop sensor 323 is disposed in pit 305 near the lowest position to which table 310 can be lowered. Loop sensor 322 is disposed in pit 305 at a higher position than loop sensor 323. Loop sensor 321 is disposed in pit 305 at a higher position than loop sensor 322 and at a position where the loop amount is smallest within a range (allowable range) in which processing by press system 1 can be performed normally, or at a position lower than that position.

[0039] The detection results of loop sensors 321, 322, and 323 are used by the control unit 360 to perform control to form an appropriate loop amount in the pit 305 during normal processing operation, in which the supply speed of the leveler 200 matches the average consumption speed of the feeder 400, taking into account the time when the consumption speed of the feeder 400 is zero. During processing in normal processing operation, the control unit 360 monitors the detection results of loop sensors 321, 322, and 323, and notifies the control unit 260 of the leveler 200 and the control unit 440 of the feeder 400, which will be described later, so that the loop amount is between the heights of loop sensors 321 and 323.

[0040] For example, during normal processing, the loop amount may decrease for some reason, and further decrease in the loop amount may affect the press system 1 and processing. The abnormality sensor 330 is provided to detect the decreased loop amount in such cases and safely stop the press system 1 or slow the line speed until the appropriate loop amount is reached. That is, the abnormality sensor 330 functions as an abnormality detection means that detects an abnormality when the end of the coil material 120 is not detected by the brake roll inlet sensor 240, indicating that the loop amount is smaller than a predetermined amount. The abnormality sensor 330 is located at or below the highest point of the loop amount at which the press system 1 can continue processing normally during normal processing. In this embodiment, the abnormality sensor 330 is located, for example, in a pit 305 that is lower than the floor surface 10 and near the floor surface 10.

[0041] When the control unit 360 determines that the loop amount has become small based on the detection result of the abnormality sensor 330, it notifies the control units of the other devices in the press system 1 of that information, and the control units of the other devices in the press system 1 stop each device in accordance with the notified information.

[0042] The operation switching sensor 341, the operation switching sensor 342, and the abnormality sensor 330 are sensors used for control during the end-processing operation in this embodiment. The abnormality sensor 330 switches its function between the normal operation described above and the end-processing operation described below depending on the operational state. When the operation switching sensor 341 or the operation switching sensor 342 no longer detects a loop, the control unit 360 notifies the control unit of a specific device to switch from continuous operation to discontinuous operation described below. The control unit of a specific device in the press system 1 switches from continuous operation to discontinuous operation in response to the notification from the control unit 360. The operation switching sensors 341 and 342 can also be considered as switch detection means for detecting the timing to switch from continuous operation to discontinuous operation described below. In other words, the position of the operation switching sensor 341 or the operation switching sensor 342 is determined by the type of feed length range in which the feeder feeds the coil material into the press machine each time the press machine performs one processing pass. Because the abnormality sensor 330 is a sensor shared with normal operation, a different sensor may be installed if the type of feed length range does not match.

[0043] The operation switching sensor 341 in this embodiment is provided at a position lower than the abnormality sensor 330. The operation switching sensor 342 is provided at a position lower than the operation switching sensor 341 and higher than the loop sensor 321. The operation switching sensors 341, 342 function as loop detection means that detects the presence or absence of a loop when the brake roll 250 is clamping the coil material 120. Note that the number of operation switching sensors (341, 342) may be increased or decreased depending on the convenience of the press system 1.

[0044] Here, the above-mentioned anomaly sensor 330 is used for the same purpose as the operation switching sensors 341, 342 after the timing when the end of the coil material 120 is detected by the leveler entrance sensor 210. In other words, the anomaly sensor 330 is included in the loop detection means after the end of the coil material 120 is detected by the brake roll entrance sensor 240. When the end of the coil material 120 is detected by the leveler entrance sensor 210, the anomaly sensor 330 can also be said to function as one of the switching detection means for detecting the timing to switch the press system 1 from continuous operation to discontinuous operation.

[0045] (How to use the operation switching sensors 341, 342 and the abnormality sensor) Here, we will explain how to use the three sensors. The three sensors are used based on the feed length and / or line speed according to the processing performed by the press system 1. For example, in this embodiment, to simplify the explanation, as shown in Table 1, the three sensors are used as follows depending on the feed length L:

[0046] [Table 1]

[0047] In the press system 1, as the feed length L increases, it is necessary to switch from continuous operation to discontinuous operation at an earlier timing, or in other words, when the loop amount is large (the height of the lowest point of the loop is low). For this reason, among the three sensors, the abnormality sensor 330 arranged at the highest position is used during processing where the feed length L is L1 or less. The operation switching sensor 341 arranged at the position next higher than the abnormality sensor 330 is used during processing where the feed length L is longer than L1 and L2 or less. And the operation switching sensor 342 arranged at the lowest position among the three sensors is used during processing where the feed length L is longer than L2 and L3 or less. Thus, the operation switching sensors 341, 342, and the abnormality sensor 330 are provided at positions lower than the discharge sensor 350, and a plurality of them are provided at positions with different heights according to the feed length. And the operation switching sensors 341, 342, and the abnormality sensor 330 are provided at higher positions as the feed length is shorter. For this reason, it can be said that the operation switching sensors 341, 342, and the abnormality sensor 330 are height detection means for detecting the height of the loop. Note that the feed length L is in the relationship of L1 < L2 < L3, and its value is an arbitrary number determined by the type of the range of the feed length by which the feeder feeds the coil material into the press device each time the press device performs one processing.

[0048] Note that the position of the abnormality sensor 330 is not determined by the height corresponding to the feed length, but is determined by the timing of detecting an abnormality during the normal processing operation. For this reason, the positional relationship (height relationship) between the operation switching sensors 341, 342 whose heights are determined according to the feed length and the abnormality sensor 330 is not limited to the above-described positional relationship, that is, the positional relationship in which the abnormality sensor 330 is provided at the highest position among the three sensors. For example, the abnormality sensor 330 may be provided at the lowest position among the three sensors, or may be provided between the operation switching sensor 341 and the operation switching sensor 342.

[0049] The operation switching sensors 341, 342 are positioned (at a height) such that after these sensors detect a loop, when the feeder 400 feeds the coil material 120 by one feeding length L to the press device 500, the discharge sensor 350 detects the coil material 120. Note that the operation switching sensors 341, 342 may be positioned (at a height) such that the discharge sensor 350 does not yet detect the coil material 120 even when the feeder 400 feeds the coil material 120 by one feeding length L to the press device 500.

[0050] The discharge sensor 350 is used to determine the timing (discharge timing, described later) to change the brake rolls 250 of the leveler 200, which clamp the end of the coil material 120, from a closed state to an open state. The discharge sensor 350 is used to determine the timing when the brake rolls 250, which clamp the coil material 120, release the coil material 120, and functions as a discharge detection means for detecting the coil material 120.

[0051] The discharge sensor 350 is provided at a position higher than the abnormality sensor 330 and lower than the processing height. In this embodiment, the discharge sensor 350 is provided at a position higher than the floor surface 10 and lower than the processing height. The discharge sensor 350 does not detect the coil material 120 during normal processing operation, but detects the coil material 120 after switching to the terminal processing operation.

[0052] The leveler entrance sensor 210 of the leveler 200 detects the end of the coil material 120 and switches to a closed state, and the brake roll entrance sensor 240 detects the end of the coil material 120 and stops rotating, causing the brake rolls 250 to maintain clamping of the coil material 120. In this state, as the feeder 400 continues to deliver the coil material 120, the loop rises and eventually the discharge sensor 350 detects the coil material 120. Then, the control unit 360 notifies the control unit 260 of the leveler 200 to change the brake rolls 250 from a closed state to an open state and release the coil material 120. In response to this notification, the control unit 260 of the leveler 200 controls the cylinder 280 to change the brake rolls 250 from a closed state to an open state. Note that the operation of the brake rolls 250, which have been clamping the end of the coil material 120 and stopped rotating to an open state, and releasing the end of the coil material 120 is also referred to as dispensing.

[0053] The control unit 360 controls the motor 380 based on the detection results of the contact sensor 312 in accordance with various programs stored in the storage unit 270, so that the table 310 comes into contact with the loop, in other words, so that the table 310 follows the loop. When the table 310 comes into contact with the loop, the control unit 360 temporarily stops the lifting of the table 310. When the loop subsequently rises and separates from the table 310, the control unit 360 lifts the table 310 until it comes into contact with the loop. The control unit 360 repeats this operation to make the table 310 follow the loop.

[0054] Furthermore, the control unit 360 notifies the control units of the other devices in the press system 1 to perform predetermined control based on the detection results of the loop sensors 321, 322, and 323, the abnormality sensor 330, the operation switching sensors 341 and 342, and the discharge sensor 350. The motor 380 is, for example, a geared motor, and raises the table 310 so that the table 310 can follow the loop. For example, the motor 380 may be an inexpensive motor with low accuracy in acceleration and deceleration control and a low upper limit on the ascending speed.

[0055] <Feeder> The feeder 400 is a feeding device that feeds the coil material 120 at a predetermined feed speed and a predetermined feed length to the press device 500. The feeder 400 has a feed roll 410, end sensors 420 and 430, a control unit 440, a memory unit 450, a cylinder 460, and a motor 470.

[0056] The feed rolls 410 function as a feeding means for feeding the coil material 120 to the press device 500. When a slide 512 (described later) of the press device 500 finishes processing and moves away from the coil material 120, until the next processing is started, the feed rolls 410 are in a closed state and feed the coil material 120 to the press device 500. The feed rolls 410 feed (supply) the coil material 120 to the press device 500 at a feed length and feed speed that are set according to the processing to be performed in the press device 500. The feed rolls 410 are in an open state and release the coil material 120 while processing is being performed in the press device 500. Note that, in consideration of all circumstances, it is also possible to set the feed rolls 410 to maintain a closed state and keep gripping the coil material 120.

[0057] After the end of the coil material 120 is released by the leveler 200, the end sensors 420, 430 detect the end of the coil material 120 in the feeder 400. When the end sensors 420, 430 detect the end of the coil material 120, the control unit 440 stops the feeder 400 and notifies a controller 514 (described later) of the press device 500 to stop the press device 500.

[0058] Here, the feed length differs depending on the processing performed by the press device 500, and the timing at which the end of the coil material 120 should be detected differs depending on the feed length. In other words, the longer the feed length of processing, the earlier the timing at which the end of the coil material 120 needs to be detected. For this reason, in this embodiment, two end sensors 420 and 430 are used as shown in Table 2.

[0059] [Table 2]

[0060] For example, the end sensor 420 is provided upstream of the feed roll 410 in the conveyance direction and near the feed roll 410. The end sensor 420 is used, for example, during processing where the feed length L is less than L4. On the other hand, for example, the end sensor 430 is provided upstream of the end sensor 420 in the conveyance direction. The end sensor 430 is used, for example, during processing where the feed length L is greater than or equal to L4 and less than L5. In this embodiment, the end sensor 430 is provided downstream of the loop table 300 in the conveyance direction. However, when the feed length is even longer, the end sensor may be provided on the loop table 300. That is, the number and arrangement position of the end sensors may be determined according to the feed length L. The feed length L is in the relationship of L4 < L5 and is an arbitrary value determined by the type of the range of the feed length by which the feeder feeds the coil material to the press device each time the press device performs one processing.

[0061] The cylinder 460 switches between a closed state in which the feed roll 410 holds the coil material 120 and an open state in which it does not hold the coil material 120. The motor 470 drives the rotation of the feed roll 410.

[0062] The control unit 440 controls the cylinder 460 and the motor 470 in conjunction with other devices of the press system 1 to send out the coil material 120 to the press device 500. It is assumed that the control unit 440 controls the rotation of the feed roll 410 by a known method using detection means such as an encoder. Similarly, it is assumed that the control unit 440 controls the switching between the open state and the closed state of the feed roll 410 by a known method.

[0063] The control unit 440 controls the feeder 400 in conjunction with other devices of the press system 1 in accordance with various programs stored in the memory unit 450. The memory unit 450 stores, for example, a feed length and a feed speed associated with each process, and the control unit 440 feeds the coil material 120 at a predetermined feed length and a predetermined feed speed in accordance with the process performed by the press device 500. In this embodiment, the memory unit 450 stores two feed speeds for feeding a predetermined feed length in a predetermined process. One is a feed speed during continuous operation (first feed speed), and the other is a feed speed during discontinuous operation (second feed speed), which is slower than the feed speed during continuous operation and will be described later. The feeder 400 may also have a display unit and an input unit.

[0064] <Pressing equipment> The press apparatus 500 of FIG. 1 will be described with reference to FIG. 4 as well. FIG. 4 is a schematic perspective view showing the configuration of the press apparatus 500 of this embodiment, for example, a schematic view of an integral straight-side frame or C-frame type press apparatus 500. FIG. 4 shows the conveying direction of the coil material 120, as well as the upstream, downstream, up-down, and back-and-forth directions (front and back) in the conveying direction. The press apparatus 500 is configured to include a drive motor 504 (drive means), a transmission mechanism 506, a crankshaft 508, a connecting rod 510, a slide 512, and a bolster 522 inside and outside a housing 502. The press apparatus 500 also includes a controller 514, a memory unit 515, a display unit 516, and an input unit 518. The press apparatus 500 also includes a sensor 524, a rotary encoder 525, and a gibber 526. The press machine 500 of this embodiment may be a progressive press machine that performs progressive press working (hereinafter referred to as progressive working), and in that case, has a plurality of working stages.

[0065] The drive motor 504 is, for example, a servo-controlled servo motor, and moves a mold 503 (described later) up and down via a transmission mechanism 506, a crankshaft 508, and a connecting rod 510 while controlling the amount and direction of rotation. The transmission mechanism 506 is configured to have transmission members such as gears and belts, and transmits the rotation of the motor shaft of the drive motor 504 to the crankshaft 508. A control signal to the drive motor 504 is sent from a controller 514.

[0066] Crankshaft 508 and connecting rod 510 are used to convert the rotational movement of the motor shaft transmitted by transmission mechanism 506 into reciprocating movement (up and down movement in this embodiment). Rotation of the motor shaft rotates crankshaft 508, and the rotation is transmitted to connecting rod 510, one end of which is connected to crankshaft 508, causing connecting rod 510 to move up and down (raise and lower).

[0067] The crankshaft 508 is also provided with a rotary cam switch (not shown) that outputs an ON signal or OFF signal in conjunction with the rotation of the crankshaft 508. The rotary cam switch outputs an ON signal or OFF signal, for example, when the rotation of the crankshaft 508 reaches a predetermined angle, in other words, at a predetermined timing during the machining operation. The timing at which the rotary cam switch outputs an ON signal (or an OFF signal) will hereinafter be referred to as the output timing. The controller 514 performs the machining operation in conjunction with other devices of the press system 1 based on the signal output from the rotary cam switch.

[0068] A slide 512 is connected near the other end of connecting rod 510. Slide 512 moves up and down along gibb 526 as connecting rod 510 moves up and down. In press device 500, bolster 522 is arranged opposite slide 512. Upper die 503a, as part of mold 503, is attached to the surface of slide 512 facing bolster 522 (the lower surface in this embodiment). Lower die 503b, which pairs with upper die 503a, as part of mold 503 is attached to the surface of bolster 522 facing slide 512 (the upper surface in this embodiment).

[0069] Coil material 120, which is the object to be processed, is placed between upper mold 503a and lower mold 503b, and pressed by upper mold 503a and lower mold 503b, thereby performing press processing on coil material 120 by press device 500. Coil material 120 is transported, for example, from the left (upstream) side to the right (downstream) side in Fig. 4, and hereinafter the transport direction of coil material 120 is also referred to as the left-right direction.

[0070] More specifically, the drive motor 504 rotates under the control of the controller 514. The rotation of the drive motor 504 is transmitted to the connecting rod 510 via the transmission mechanism 506 and the crankshaft 508, causing the slide 512 to move up and down. The downward movement of the slide 512 presses the upper die 503a and the lower die 503b together, thereby performing press processing on the coil material 120. That is, in the press device 500, the drive motor 504, the transmission mechanism 506, the crankshaft 508, the connecting rod 510, and the slide 512 constitute a press unit. The transmission mechanism 506 is provided with a rotary encoder 525, which is a rotation speed detection means for detecting the rotation speed of the crankshaft 508. The controller 514 can detect the position of the slide 512 by detecting the rotation speed of the crankshaft using the rotary encoder 525.

[0071] The sensor 524, which is a load detection means for detecting the load during processing, is a sensor, such as a load cell, for detecting the load acting on the connecting rod 510 when the press device 500 presses the coil material 120. The sensor 524 may be, for example, a strain gauge installed in the housing 502. The sensor 524 may be installed at any position on the connecting rod 510 (for example, a position near the center). Furthermore, multiple sensors 524 may be installed, and for example, the sensors may detect strain on the left and right sides of the housing 502, respectively, and the detected results may be added up to determine the total load. In FIG. 4, the side on which the display unit 516 is located is the front side of the press device 500.

[0072] The controller 514 controls the press apparatus 500 in accordance with various programs stored in the memory unit 515. The display unit 516 displays data indicating the status of the press apparatus 500. The input unit 518 is used to input data necessary to operate the press apparatus 500. The input unit 518 is used when the user inputs parameters necessary for processing. The controller 514 controls the press apparatus 500 and other devices in the press system 1 so that they work together to perform processing.

[0073] Furthermore, the control units and controllers of each device in the press system 1 are assumed to transmit and receive information and signals to and from other devices using known communication means. While the explanation of FIGS. 1 and 2 illustrates the control units of each device in the press system 1 operating in cooperation with other control units, this is not limited to this. For example, a separate control unit may be provided to control the entire press system 1, and this overall control unit may control the control units of each device. Furthermore, a specific device may not have a control unit and may be controlled by the control unit of another device, as long as the normal processing operation and the terminal processing operation can be controlled by the entire press system 1. The control units 260, 360, 440, and controller 514 are included in the control means that control the leveler 200, loop table 300, feeder 400, and press device 500, in other words, the press system 1.

[0074] <Conventional termination processing operation> A conventional terminal end processing operation will be described below for comparison with the terminal end processing operation of this embodiment, which will be described later. When the leveler entrance sensor 210 of the leveler 200 detects the terminal end of the coil material 120, the press system 1 switches from normal processing operation to terminal end processing operation. At this timing, the control unit 260 of the leveler 200 sets the speed at which the coil material 120 is conveyed (hereinafter referred to as the operating speed) to an operating speed (hereinafter referred to as the terminal end operating speed) that is slower than the operating speed during normal processing operation (hereinafter referred to as the normal operating speed). The terminal end operating speed is set, for example, to a speed that allows the operation of the leveler 200 to be stopped immediately when the brake roll entrance sensor 240 transmits light. Thereafter, when the brake roll entrance sensor 240 detects the terminal end of the coil material 120, the control unit 260 stops the rotation of the brake roll 250 by the motor 290, thereby stopping the operation of the leveler 200. As a result, the brake roll 250 is in a closed state, and the brake roll 250, which has stopped rotating, maintains a state in which it clamps the terminal end of the coil material 120. As a result, the supply of the coil material 120 from the leveler 200 to the loop table 300 is stopped.

[0075] If the loop comes into contact with the table 310 on the loop table 300 while the leveler 200 is operating at the terminal operating speed, the control unit 260 stops the leveler 200 (including the brake roll 250). After the operation of the leveler 200 is stopped, when the loop becomes smaller and separates from the table 310 again, the control unit 260 resumes operation of the leveler 200 at the terminal operating speed. The control unit 260 repeats this operation from the start of the terminal processing operation until the brake roll inlet sensor 240 detects the terminal end of the coil material 120. The control unit 260 notifies the control unit 260 of contact / non-contact information between the loop and the table 310 based on the detection result of the contact sensor 312.

[0076] Meanwhile, the operations of the feeder 400 and the press device 500 differ depending on the feed length and line speed of the processing being performed at that time. For ease of explanation, the case where the feed length is less than 500 mm and the line speed is less than 15 m / min will be referred to as pattern 1, and the case where the feed length is 500 mm or more and the line speed is 15 m / min or more will be referred to as pattern 2. Note that patterns 1 and 2 will be classified in the same way in the present embodiment described below.

[0077] (Pattern 1) For example, if the feed length is less than 500 mm and the line speed is less than 15 m / min, even if the leveler 200 stops, the press device 500 does not stop and continues to operate continuously. This type of operation is referred to as pattern 1. In pattern 1, the loop amount in the loop table 300 becomes smaller as processing progresses, and the lowest point of the loop rises. In pattern 1, because the line speed is less than 15 m / min, the table 310 can rise while following the rise of the loop.

[0078] As the loop rises, and the table 310 eventually reaches or exceeds the material dischargeable height h1, or the discharge sensor 350 detects the coil material 120, the control unit 260 of the leveler 200 opens the brake rolls 250 using the cylinder 280. That is, the control unit 260 opens the brake rolls 250 using the cylinder 280 at the earlier of the timing when the table 310 reaches or exceeds the material dischargeable height h1, or the timing when the discharge sensor 350 detects the coil material 120. As a result, the end of the coil material 120 that was clamped by the brake rolls 250 is released (discharged) and discharged onto the loop table 300.

[0079] In the case of pattern 1, continuous operation continues, but even if the end of coil material 120 is dispensed, table 310 follows coil material 120 and rises to a predetermined height, so it can safely receive the end of the discharged coil material 120. Therefore, if the end of coil material 120 is not received, the end of coil material 120 will not fall into pit 305 and cause damage to the device or equipment, and the coil material 120 itself will not be damaged.

[0080] After dispensing, processing continues in the press device 500, and when the end of the coil material 120 is detected by the end sensor 420 of the feeder 400, the control unit 440 of the feeder 400 stops the feeder 400 and notifies the controller 514 of the press device 500 to stop the press device 500.

[0081] (Pattern 2) Next, a case where the feed length is 500 mm or more or the line speed is 15 m / min or more will be described below as pattern 2. In pattern 2, if the press device 500 is operated continuously after the leveler 200 has stopped, the table 310 will be unable to keep up with the rise of the loop. This is because the table 310 is driven by a motor 380, such as a geared motor, and there is an upper limit to the speed at which the table 310 can rise. If the end of the coil material 120 is discharged from the leveler 200 in this state, the end of the coil material 120 will not be caught and will fall into the pit 305, potentially damaging the equipment or facilities, or potentially damaging the coil material 120 itself. Furthermore, if the end of the coil material 120 is discharged while the loop is rising too fast, the coil material 120 will bounce upward, potentially damaging the equipment or facilities, or potentially damaging the coil material 120 itself.

[0082] For this reason, in pattern 2, conventionally, when the leveler 200 stops, the press device 500 moves the slide 512 to the top dead center and temporarily stops processing. Meanwhile, the feeder 400 reduces the feed speed of the feed roll 410 and feeds the coil material 120 to the temporarily stopped press device 500 by the feed length. After the coil material 120 has been fed, the press device 500 reduces its rotational speed and resumes processing, and once the resumed processing is completed, it once again stops. In this way, with the press device 500 reducing its rotational speed and the feeder 400 reducing its feed speed, an operation in which the feeder 400 and the press device 500 operate alternately (hereinafter referred to as alternating operation) is started.

[0083] As described above, in the case of conventional pattern 2, when the press system 1 transitions to the terminal processing operation, alternating operation is performed. During alternating operation, the speed of the loop ascent slows, allowing the table 310 to rise to the height of the loop and catch up with it. Thereafter, the table 310 follows the loop and rises by repeating the operation of stopping when it comes into contact with the loop and rising when it separates from the loop. Specifically, the table 310 stops by deceleration control when it comes into contact with the loop, and rises at a predetermined rising speed by acceleration control when it separates from the loop.

[0084] As the loop rises, and table 310 eventually reaches or exceeds material discharge height h1, or when discharge sensor 350 detects coil material 120, control unit 260 of leveler 200 opens brake roll 250 using cylinder 280. This releases the end of coil material 120 that was clamped by brake roll 250, and the coil material is discharged onto loop table 300. In pattern 2, alternating operation allows table 310 to follow the loop, so even if the end of coil material 120 is dispensed, table 310 can safely receive the discharged end of coil material 120. Therefore, there is no risk of the coil material 120 failing to be received and falling into pit 305, damaging equipment or facilities, and there is no risk of the coil material 120 itself being damaged.

[0085] When the end of the coil material 120 is discharged from the leveler 200, the feeder 400 and the press device 500 change from alternating operation to continuous operation. After that, the operation is the same as in pattern 1, so a description thereof will be omitted.

[0086] As described above, in the conventional pattern 2, the press system 1 is operated alternately from the time when the leveler 200 stops until the coil material 120 is discharged from the leveler 200, which causes a problem of reduced productivity. In particular, when the feed length is short (for example, 510 mm) under the conditions of pattern 2, the reduction in productivity becomes significant.

[0087] <Termination Processing Operation of This Embodiment> In this embodiment, alternating operation as in the past is not performed, particularly in the above-described pattern 2, when the feed length is equal to or shorter than a predetermined feed length. In this embodiment, the press system 1 continues continuous operation even after the leveler 200 stops, and switches to discontinuous operation when the operation switching sensor 341, the operation switching sensor 342, or the abnormality sensor 330 can no longer detect a loop. Here, discontinuous operation refers to an operation in which the press device 500 stops, for example, once, and during that time the feeder 400 feeds the coil material 120 at a low speed for one feed length, as will be described later. Note that the operation of pattern 1 in this embodiment is similar to the operation of conventional pattern 1, and therefore a description thereof will be omitted.

[0088] 5 is a flowchart illustrating the end processing operation of this embodiment. In step (hereinafter referred to as S) 100, the press system 1 starts processing the coil material 120. In S102, the press system 1 determines, via the control unit 260 of the leveler 200, whether or not the leveler entrance sensor 210 has detected the end of the coil material 120. If the press system 1 determines in S102 that the leveler entrance sensor 210 has not detected the end of the coil material 120, it returns the process to S102, and if it determines that the end has been detected, it proceeds to S104.

[0089] In S104, the press system 1 starts the terminal processing operation. Specifically, the control unit 260 of the leveler 200 closes the brake roll 250 via the cylinder 280 and changes the normal operating speed to the terminal operating speed. The brake roll 250 rotates as driven by the motor 290. At this timing, the control unit 440 of the feeder 400 and the controller 514 of the press device 500 also continue continuous operation.

[0090] In S106, the press system 1 determines, via the control unit 260 of the leveler 200, whether or not the brake roll entrance sensor 240 has detected the end of the coil material 120. If the press system 1 determines in S106 that the brake roll entrance sensor 240 has not detected the end of the coil material 120, it returns the process to S106, and if it determines that the end has been detected, it proceeds to S108.

[0091] In S108, the press system 1 causes the control unit 260 of the leveler 200 to stop the rotation of the brake roll 250 via the motor 290. As a result, the end of the coil material 120 is clamped by the brake roll 250, which has stopped rotating, i.e., the leveler 200 is stopped (clamping process). Meanwhile, because the feed roll 410 of the feeder 400 continues to operate continuously, the amount of loop of the coil material 120 on the loop table 300 decreases thereafter, and the lowest point of the loop rises (continuous operation process).

[0092] At this time, the table 310 starts to rise following the loop to a certain height h2. Here, the certain height h2 is a height different from the material dischargeable height h1, and is set at a position lower than the material dischargeable height h1 (h2

[0093] ​The control unit 360 stops the lifting of the table 310 when it determines, based on the detection result of the encoder 315, that the table 310 has risen to a certain height h2. This is because if the table 310 rises to a position higher than the certain height h2 before the low-speed feed step described below, the table 310 may push up the loop. Furthermore, for example, if the lifting speed of the table 310 is fast enough to keep up with the lifting of the loop, the operation switching sensors 341, 342 and the abnormality sensor 330 may detect the table 310 instead of the loop, resulting in a false detection. Here, the operation switching sensors 341, 342 and the abnormality sensor 330 detecting the table 310 means that the table 310 blocks light from the operation switching sensors 341, 342 and the abnormality sensor 330.

[0094] In S110, the press system 1 determines whether the pattern is pattern 2 described above. If the press system 1 determines in S110 that the pattern is pattern 1 and not pattern 2, the process proceeds to S143. If the press system 1 determines that the pattern is pattern 2, the process proceeds to S112. In S112, the press system 1 determines whether the feed length is equal to or shorter than a predetermined feed length. S1 1 If the press system 1 determines in step S122 that the feed length is longer than the predetermined feed length, the process proceeds to step S146. If the press system 1 determines that the feed length is equal to or shorter than the predetermined feed length, the process proceeds to step S114. The predetermined feed length is, for example, the aforementioned L3. During the processes from step S114 to step S122, the feeder 400 and the press device 500 are in discontinuous operation.

[0095] In S114, the press system 1 determines whether the operation changeover sensor 341, the operation changeover sensor 342, or the abnormality sensor 330 can no longer detect the loop and whether the table 310 has risen to a certain height h2, using the control unit 360 of the loop table 300. Here, as described above, which of the three sensors, the operation changeover sensor 341, the operation changeover sensor 342, and the abnormality sensor 330, is used to perform S11. 4 Whether to make this determination is determined based on the feed length L.

[0096] If the press system 1 determines in S114 that the above-mentioned conditions are not satisfied, the process returns to S114. If the press system 1 determines in S114 that the operation switching sensor 341, the operation switching sensor 342, or the abnormality sensor 330 can no longer detect a loop and that the table 310 has risen to a certain height h2, the process proceeds to S116 (detection step).

[0097] In S116, the press system 1 stops the lifting of the table 310 of the loop table 300. Furthermore, the press system 1, after the processing currently being performed is completed, causes the controller 514 of the press device 500 to temporarily stop the press device 500 without starting processing of the next fed coil material 120 (stopping process). Note that the control of temporarily stopping the press device 500 during processing is a well-known technique, and therefore a description thereof will be omitted. Furthermore, at this timing, the feeder 400 sets the feed speed when feeding the coil material 120 to the press device 500 to a feed speed (second feed speed) (hereinafter also referred to as a low feed speed) that is slower than the feed speed during continuous operation (first feed speed). The control unit 440 of the feeder 400 feeds the coil material 120 by one feed length at the low feed speed to the temporarily stopped press device 500 (hereinafter also referred to as a low-speed feed) (low-speed feed process).

[0098] In S118, the press system 1 determines whether the low-speed feeding is complete, i.e., whether the coil material 120 has been fed for one feed length at the low feed speed. If the press system 1 determines in S118 that the low-speed feeding is complete, the process proceeds to S120. If the press system 1 determines that the low-speed feeding is not complete, the process proceeds to S132. In S120, the press system 1 stops the feeder 400 and causes the control unit 360 of the loop table 300 to raise the table 310 via the motor 380. As described above, in processing corresponding to pattern 2, the loop rises too quickly and the table 310 is unable to keep up with the loop. In this embodiment, the table 310 is raised after the low-speed feeding is complete.

[0099] In S122, the press system 1 determines, via the control unit 360 of the loop table 300, whether or not the table 310 has come into contact with the loop using the contact sensor 312, in other words, whether or not the table 310 has caught up with the loop. If the press system 1 determines in S122 that the table 310 is not in contact with the loop, it returns the process to S122, and if it determines that the table 310 has come into contact, it proceeds to S124. With the process up to this point, in this embodiment, even in pattern 2, the table 310 is in a state where it can safely receive the coil material 120 that is subsequently dispensed by the leveler 200.

[0100] In S124, the press system 1 stops the lifting of the table 310 using the control unit 360 of the loop table 300. The press system 1 also controls the control unit 260 of the leveler 200 to open the brake roll 250 via the cylinder 280. This releases (discharges) the end of the coil material 120 from the leveler 200. In S126, the press system 1 transitions from discontinuous operation to continuous operation, resumes continuous operation, and ends the process. That is, the press device 500 resumes the processing that was temporarily stopped. Note that the control for restarting the press device 500 that was temporarily stopped is a well-known technique, so a description thereof will be omitted. The feeder 400 also returns the feed speed of the feed roll 410 from a low speed to the feed speed during continuous operation.

[0101] After this, the press system 1 determines whether the end sensor 420 or the end sensor 430 has detected the end of the coil material 120 using the control unit 440 of the feeder 400. As described above, which of the two sensors, the end sensor 420 or the end sensor 430, to use is determined based on the feed length L. When the end sensor 420 or the end sensor 430 detects the end of the coil material 120, the press system 1 completes the processing currently being performed and then stops operation. Specifically, the control unit of each device stops each device. Since the control of deceleration and other processes performed before stopping the operation of the press system 1 are well-known techniques, a description thereof will be omitted. After this, a new coil material 120 is attached to the uncoiler 100, the starting end of the coil material 120 is pulled out, and the coil material 120 is set in each device, and processing by the press system 1 resumes.

[0102] In S132, the press system 1 determines, via the control unit 360 of the loop table 300, whether or not the discharge sensor 350 has detected the coil material 120. If the press system 1 determines in S132 that the discharge sensor 350 has not detected the coil material 120, it returns the process to S118, and if it determines that the coil material 120 has been detected, it proceeds to S134. In S134, the press system 1 causes the control unit 440 of the feeder 400 to temporarily stop the low-speed feed. In S136, the press system 1 causes the control unit 360 of the loop table 300 to lift the table 310.

[0103] In S138, the press system 1 determines whether or not the table 310 has come into contact with the loop using the contact sensor 312 of the loop table 300 via the control unit 360. If the press system 1 determines in S138 that the table 310 has not come into contact with the loop, it returns the process to S138, and if it determines that the table 310 has come into contact with the loop, it proceeds to S140.

[0104] In S140, the press system 1 stops the lifting of the table 310 using the control unit 360 of the loop table 300. Also, the press system 1 opens the brake roll 250 (dispense) using the control unit 260 of the leveler 200. Then, the press system 1 feeds the remaining portion of the coil material 120 that was stopped midway by the feeder 400 to the press device 500 at a low feed speed. In S142, the press system 1 determines whether the low-speed feed has been completed, and if it determines that the low-speed feed has not been completed, the process returns to S142, and if it determines that the low-speed feed has been completed, the process proceeds to S126.

[0105] If the result of S110 is pattern 1, the press system 1 maintains continuous operation in S143. In S144, the press system 1 determines whether the table 310 is located higher than the material dischargeable height h1. If the press system 1 determines that the table 310 is located higher than the material dischargeable height h1, the process proceeds to S124. If the press system 1 determines that the table 310 is not located higher than the material dischargeable height h1, the process returns to S144. Also, if the feed length is longer than the predetermined feed length in S112, the press system 1 transitions to alternating operation in S146, as in the conventional case. In S147, the press system 1 determines whether the discharge sensor 350 has detected the coil material 120. If the press system 1 determines that the discharge sensor 350 has not detected the coil material 120 in S147, the process returns to S147. If the press system 1 determines that the coil material 120 has been detected, the process proceeds to S124.

[0106] As described above, the press system of this embodiment performs continuous operation, in which the feeder and press machine are continuously operated, even after the brake rolls clamp the end of the coil material, until the operation changeover sensor (or abnormality sensor) detects the absence of a loop. Thereafter, when the operation changeover sensor (or abnormality sensor) detects the absence of a loop, the press system stops the press machine and feeds the coil material by a predetermined feed length at a feed speed slower than the feed speed during continuous operation. Here, the press system stops the press machine only once. This allows the end processing operation to be performed without stopping the press machine as much as possible, even in a large press system. Furthermore, because the time the press machine is stopped is the time it takes to transport one feed length of the coil material 120, the time from when the press machine is stopped to when it is restarted can be minimized.

[0107] Although the preferred embodiments of the present invention have been described above, the present invention is not limited to these, and various modifications and changes are possible within the scope of the gist thereof, such as the following modifications.

[0108] For example, the loop table 300 may have a detection means for detecting the height of the table 310, and the elevation of the table 310 may be controlled based on the detection result of this detection means.

[0109] For example, in this embodiment, the feed speed of the feed roll 410 is slowed down in S114 of Fig. 5 to feed the coil material 120 by one feed length, but this is not limited to this. For example, the rotation of the feed roll 410 may be stopped for a predetermined time, in other words, the feeding of the coil material 120 may be stopped, and once the table 310 has caught up with the loop, the coil material 120 may be fed at a slow feed speed. In this way, a slow feed speed and a stop may be combined with each other regarding the feed speed.

[0110] For example, in S124 of Figure 5, the feed speed of the feed roll 410 is returned from a low speed to the original feed speed, but if safety is emphasized, such as suppressing flapping at the end of the coil material 120, the speed may remain low.

[0111] For example, in the above-described embodiment, when the end sensors 420, 430 of the feeder 400 detect the end of the coil material 120, the feeder 400 and the press device 500 are stopped (S128 in FIG. 5). However, further processing may be performed on the remaining portion of the coil material 120 thereafter. For example, the feeder 400 may have a known micro-feeder (not shown). If the feeder 400 has a micro-feeder, the remaining number of times that the press device 500 can perform processing is calculated based on the movement amount and feed length of the micro-feeder. The micro-feeder transports the coil material 120 of the length corresponding to the calculated remaining number of times, thereby allowing the press device 500 to resume continuous or alternating operation. When the coil material 120 fed by the micro-feeder has been processed the calculated remaining number of times, the feeder 400 and the press device 500 are stopped. Such control may be performed after the processing of S126 in FIG. 5.

[0112] As described above, according to this embodiment, it is possible to provide a press system and a method for controlling the press system that can prevent productivity from decreasing as much as possible even when the coil material is near the end.

[0113] [Objective 1] The press system of the present invention comprises: A straightening device for straightening a curl of a coil material, the straightening device having an end detection means for detecting an end of the coil material, and a clamping means for clamping the end of the coil material when the end detection means detects the end of the coil material; a press device for processing the coil material; a feeding device that feeds the coil material to the press device at a predetermined feeding speed and a predetermined feeding length at a time; a loop forming device that bends the coil material between the straightening device and the feeding device to form a loop, the loop forming device having: a discharge detection means that detects the timing when the clamping means that clamps the end of the coil material releases the coil material; and a support section that rises as the loop rises to support the loop; a control means for controlling the straightening device, the pressing device, the feeding device, and the loop forming device; A press system comprising: the loop forming device has a loop detection means for detecting the presence or absence of the loop while the clamping means is clamping the end of the coil material, The control means performs continuous operation by continuously operating the feeding device and the press device until the loop detection means detects that there is no loop, even after the clamping means has clamped the end of the coil material, and when the loop detection means detects that there is no loop, stops the press device and feeds the coil material by the specified feed length using the feeding device at a feed speed slower than the feed speed during the continuous operation.

[0114] [Objective 2] The control means may stop the press device only once when the loop detection means detects the absence of the loop.

[0115] [Objective 3] The discharge detection means is provided at a position lower than the processing height of the straightening device, The loop detection means may be provided at a position lower than the discharge detection means, and a plurality of loop detection means may be provided at positions different in height.

[0116] [Objective 4] The loop detection means may be provided at a higher position as the feed length becomes shorter.

[0117] [Objective 5] the loop forming device has an abnormality detection means for detecting, when the end of the coil material is not detected by the end detection means, that the amount of the loop is smaller than a predetermined amount, which is abnormal; The abnormality detection means may be included in the loop detection means after the end of the coil material is detected by the end detection means.

[0118] [Objective 6] The abnormality detection means may be provided at the highest position among the plurality of loop detection means.

[0119] [Objective 7] The method for controlling a press system of the present invention includes: a press machine that processes the coil material; a feeding device that feeds the coil material to the press machine at a predetermined feed speed and a predetermined feed length at a time; a loop forming device that bends the coil material between the straightening device and the feeding device to form a loop, the loop forming device having a discharge detection device that detects the coil material and is used to determine when the clamping device that clamps the end of the coil material will release the coil material, and a support part that rises as the loop rises to support the loop; and a control means that controls the straightening device, the press machine, the feeding device, and the loop forming device, the loop forming device has a loop detection means for detecting the presence or absence of the loop while the clamping means is clamping the end of the coil material, a clamping step in which the clamping means clamps the terminal end of the coil material; a continuous operation step of continuously operating the feed device and the press device by the control means until the loop detection means detects the absence of the loop; a detection step in which the loop detection means detects the absence of the loop; a stopping step of stopping the press device by the control means; a low-speed feeding step of feeding the coil material by the predetermined feed length at a feed speed slower than the feed speed during the continuous operation by the feeding device; Equipped with. [Explanation of symbols]

[0120] 1 Press System 10 Floor 100 Uncoiler 110 Mandrel 120 Coil material 130 Control Unit 140 Drive Unit 200 Leveller 210 Leveler entrance sensor 220 Entrance Roll 230 Work Roll 240 Brake roll entrance sensor 250 Brake Roll 260 Control Unit 270 Storage section 280 cylinders 290 Motor 300 Loop Table 305 Pit 310, 310H, 310L tables 312 Contact Sensor 315 Encoder 321, 322, 323 Loop Sensors 330 Abnormal Sensor 341, 342 Operation switching sensor 350 Emission Sensor 360 Control Unit 370 Storage section 380 Motor 400 Feeder 410 Feed Roll 420, 430 End Sensor 440 Control Unit 450 Storage section 460 cylinders 470 Motor 500 Press Equipment 502 Case 503 Molds 503a Upper mold 503b lower mold 504 Drive motor 506 Transmission Mechanism 508 crankshaft 510 connecting rod 512 slides 514 Controller 515 Storage section 516 Display section 518 Input section 522 Bolster 524 Sensors 525 rotary encoder 526 give

Claims

1. A straightening device for straightening a curl of a coil material, the straightening device having an end detection means for detecting an end of the coil material, and a clamping means for clamping the end of the coil material when the end detection means detects the end of the coil material; a press device for processing the coil material; a feeding device that feeds the coil material to the press device at a predetermined feeding speed by a predetermined feeding length; a loop forming device that bends the coil material between the straightening device and the feeding device to form a loop, the loop forming device having: a discharge detection means that detects the timing when the clamping means that clamps the end of the coil material releases the coil material; and a support section that rises as the loop rises to support the loop; a control means for controlling the straightening device, the pressing device, the feeding device, and the loop forming device; A press system comprising: the loop forming device has a loop detection means for detecting the presence or absence of the loop while the clamping means is clamping the end of the coil material, The control means Even after the clamping means has clamped the end of the coil material, a continuous operation is performed in which the feeding device and the press device are continuously operated until the loop detection means detects that there is no loop, When the loop detection means detects the absence of the loop, the press system stops the lifting of the support part and stops the press device, and performs discontinuous operation in which the feed device feeds the coil material at a feed speed slower than the feed speed during the continuous operation, and when the coil material has been fed one time by the specified feed length, the feed device stops and starts lifting the support part, and after the support part comes into contact with the loop, the clamping means is released and the continuous operation is resumed.

2. 2. The press system according to claim 1, wherein the control means stops the press device only once when the loop detection means detects the absence of the loop.

3. The discharge detection means is provided at a position lower than the processing height of the straightening device, 3. The press system according to claim 2, wherein the loop detection means is provided at a position lower than the discharge detection means and a plurality of the loop detection means are provided at positions different in height.

4. 4. The press system according to claim 3, wherein the loop detection means is provided at a higher position as the feed length becomes shorter.

5. the loop forming device has an abnormality detection means for detecting, when the end of the coil material is not detected by the end detection means, that the amount of the loop is smaller than a predetermined amount, which is abnormal; 5. The press system according to claim 3, wherein the abnormality detection means is included in the loop detection means after the end of the coil material is detected by the end detection means.

6. 6. The press system according to claim 5, wherein the abnormality detection means is provided at the highest position among the plurality of loop detection means.

7. a press machine that processes the coil material; a feeding device that feeds the coil material to the press machine at a predetermined feed speed and a predetermined feed length at a time; a loop forming device that bends the coil material between the straightening device and the feeding device to form a loop, the loop forming device having a discharge detecting device that detects the coil material and is used to determine when the clamping device that clamps the end of the coil material will release the coil material, and a support part that rises as the loop rises to support the loop; and a control device that controls the straightening device, the press machine, the feeding device, and the loop forming device, the loop forming device has a loop detection means for detecting the presence or absence of the loop while the clamping means is clamping the end of the coil material, a clamping step in which the clamping means clamps the terminal end of the coil material; a continuous operation step of continuously operating the feed device and the press device by the control means until the loop detection means detects the absence of the loop; a detection step in which the loop detection means detects the absence of the loop; a stopping step of stopping the lifting of the support part and stopping the press device by the control means; a low-speed feeding step in which the coil material is fed by the feeding device at a discontinuous operation at a feeding speed slower than the feeding speed in the continuous operation step, and the coil material is fed by the predetermined feeding length once; a discharging step of stopping the feeding device after one feeding of the coil material by the predetermined feeding length and starting to raise the support part, and separating the clamping means after the support part comes into contact with the loop, and resuming the continuous operation; A method for controlling a press system, comprising:

Images