Press system and method for controlling press system

Abstract

To provide a press system and a control method of the press system capable of minimizing, as much as possible, the amount of loops formed on the upstream side of a feeder in the conveying direction of a coil material.SOLUTION: A press system 1 comprises: a leveler 200; a press device 500; a feeder 400; and a controller 514 that controls the leveler 200, the press device 500, and the feeder 400. The press system further comprises an input unit 518 to which information on the press device 500 and information on the feeder 400 are inputted. The controller 514 is configured to: determine, on the basis of the information on the press device 500 and the information on the feeder 400 inputted from the input unit 518, a conveying amount of coil materials conveyed by the feeder 400 throughout a cycle time being time corresponding to a rotation speed of the press device 500, and determine control information for controlling the leveler 200 so that the leveler 200 conveys the conveying amount of the coil materials throughout the cycle time.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 the coil material is arranged in the following order from upstream to downstream in the conveying direction: uncoiler, leveler, loop table, feeder, and press device, and each device cooperates to perform processing (see, for example, Patent Document 1). The feeder intermittently conveys a fixed length of coil material (hereinafter referred to as the feed length) to the press device in accordance with the rotational movement (processing operation) of the press device. The feeder is controlled to perform high acceleration and deceleration in accordance with the processing of the press device. On the other hand, the uncoiler and leveler have longer acceleration and deceleration times than the feeder due to the large inertia of the device and the coil material. The loop table forms a bent portion of the coil material (hereinafter referred to as a loop) to absorb the speed difference between the leveler on the upstream side and the feeder on the downstream side.

[0003] The loop table has a detection means such as a photoelectric sensor, and controls the length of the loop (hereinafter referred to as the loop amount) based on the detection results of the detection means, and the leveler also performs start-up and speed control based on the detection results of the detection means of the loop table. When the detection means of the loop table detects that the loop amount is large, the leveler stops conveying the coil material (in other words, stops operation), and when it detects that the loop amount is small, the leveler resumes conveying the coil material (in other words, restarts). In order to reduce the number of times the leveler stops and restarts, the loop amount is formed large in the loop table. [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, conventional press systems have a problem in that the total length of the press system line is long due to the large loop amount. Furthermore, a large loop amount means a large weight of the loop (hereinafter referred to as "loop weight"), which increases the force pulling the coil material back upstream in the conveying direction. This limits the feeder and press device, such as the inability to increase the rotation speed of the processing operation. For these reasons, it is necessary to minimize the loop amount formed upstream of the feeder in the conveying direction of the coil material.

[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 minimize the amount of loop formed upstream of the feeder in the conveying direction of the coil material. [Means for solving the problem]

[0007] In order to solve the above problems, the present invention has the following configuration.

[0008] (1) a straightening device that conveys a coil material while straightening the coiling curl 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 control means for controlling the straightening device, the pressing device, and the feeding device; A press system comprising: an input unit into which information about the press device and information about the feed device are input; The control means determines a transport amount of the coil material to be transported by the feeding device during a cycle time, which is a time period corresponding to the rotation speed of the press device, based on information about the press device and information about the feeding device input from the input unit, and determines control information for controlling the straightening device so that the straightening device transports the transport amount of the coil material during the cycle time.

[0009] 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]

[0010] According to the present invention, it is possible to provide a press system and a method for controlling a press system that can minimize the amount of loop formed upstream of the feeder in the conveying direction of the coil material. [Brief explanation of the drawings]

[0011] [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 perspective view showing the configuration of a press device according to an embodiment. [Figure 4] FIG. 4(a) is a diagram showing the possible feed angle in the embodiment, and FIG. 4(b) is a diagram showing the feed speed and feed length of the feeder and the speed of the leveler. [Figure 5] FIG. 5(a) is a graph showing the cumulative feed amount of the coil material conveyed by the feeder of the embodiment, and FIG. 5(b) is a graph showing the cumulative feed amount of the coil material conveyed by the leveler. [Figure 6]6A and 6B are graphs showing the change in loop holding amount caused by the speed difference between a conventional feeder and a leveller for comparison with the embodiment, where FIG. 6A is a graph showing the case where the start timing of the leveller is earlier than the start timing of the feeder, and FIG. 6B is a graph showing the case where the start timing of the leveller is approximately the same as the start timing of the feeder. [Figure 7] FIG. 7(a) is a diagram showing a bending tendency that occurs in a loop table according to an embodiment, and FIG. 7(b) is a diagram showing a setting screen according to an embodiment. [Figure 8] FIG. 8 is a graph showing the change in the loop retention amount when the start timing of the leveler of the embodiment is controlled. FIG. 8(a) is a graph showing the case where the initial loop retention amount is 0, and FIG. 8(b) is a graph showing the case where the initial loop retention amount is equal to the feed length. DETAILED DESCRIPTION OF THE INVENTION

[0012] In the following explanation, the height of the coil material being transported while processing is being performed in the press device of the press system (for example, the height relative to the floor surface on which the press system is installed) is referred to as the processing height. Also, the length of the coil material that the feeder feeds 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 feed length is referred to as the feed rate. The feed length is the length of the coil material that the feeder feeds into the press device each time the press device performs one processing (also referred to as one stroke).

[0013] Furthermore, the length of the coil material 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)). The line speed is calculated based on the feed length and the rotation speed of the press machine. 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.

[0014] [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, the upstream, downstream, up-down direction, and processing height (dashed lines). 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. FIG. 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. 1 and 2.

[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 conveys (also referred to as feeding or feeding out) the coil material 120 while straightening 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. In other words, the leveler 200 conveys 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 includes an R guide 205 , an entrance roll 220 , a plurality of work rolls 230 , a controller 240 , a brake roll 250 , a control unit 260 , a memory unit 270 , a cylinder 280 , and a motor 290 .

[0019] 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.

[0020] 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.

[0021] The brake roll 250 is in a closed state to clamp the coil material 120, and in an open state to release the coil material 120. The brake roll 250 is in an open state when there is a sufficient amount of coil material 120. When the brake roll 250 is in an open state, the brake roll 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, that is, the brake roll 250 may be stopped from rotating. The brake roll 250 may be in a closed state to rotate and transport the coil material 120.

[0022] The cylinder 280 switches the entrance roll 220 and the brake roll 250 between a closed state and an open state. It is sufficient for the cylinder 280 to be of a reciprocating type, and for example, a spring may be used. The motor 290 drives the rotation of the entrance roll 220, the work roll 230, and the brake roll 250. When the start timing and line speed of the leveler 200 are calculated by the calculation of this embodiment, which will be described later, the controller 240 controls the motor 290 in accordance with the start timing and line speed. The R guide 205 imparts a predetermined curvature to the coil material 120 conveyed from the leveler 200. Since the coil material 120 is fed along the R guide 205, it is conveyed to the loop table 300 without being bent.

[0023] 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 feeding the coil material 120 to the loop table 300. The control unit 260 controls the rotation of the entrance roll 220, the work roll 230, and the brake roll 250 by a known method using a detection means (not shown), such as an encoder. Similarly, the control unit 260 controls the switching between the open and closed states of the entrance roll 220 and the brake roll 250 by a known method. The control unit 260 controls the leveler 200 in conjunction with other devices in the press system 1 in accordance with various programs stored in the memory unit 270. The leveler 200 may also have a display unit and an input unit.

[0024] <Loop table> 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 below the processing height to form a loop-shaped portion (hereinafter simply referred to as the loop), thereby providing the coil material 120 with a buffer during the conveyance process. In this way, the loop table 300 absorbs 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 is also referred to as the loop amount, and a long loop length is expressed as a large loop amount, and a short loop length is expressed as a small loop amount. 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.

[0025] The loop table 300 includes a table 310, an encoder 315, a loop sensor 321, a control unit 360, a memory unit 370, and a motor 380. The table 310 supports the loop of the coil material 120. In FIG. 1, the loop sensor 321 is represented by a black triangle. The table 310 functions as a support unit that rises as the loop rises and supports the loop. The encoder 315 detects the height of the table 310 and notifies the control unit 360 of the information regarding the height of the table 310.

[0026] The loop sensor 321 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 loop of coil material 120 is located at the position of the loop sensor 321, the light emitted from the light-emitting unit is blocked by the coil material 120, and the loop sensor 321 outputs, for example, a low-level signal. On the other hand, when the lowest point of the loop of coil material 120 passes the position of the loop sensor 321 and rises, the light emitted from the light-emitting unit is received by the light-receiving unit (hereinafter also referred to as light passing), and the loop sensor 321 outputs, for example, a high-level signal. Note that the logic of the signal output from the loop sensor 321 may be reversed. For example, 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, and if it is not safe or in a steady state, a low-level signal may be output.

[0027] In this embodiment, the loop sensor 321 detects the amount of loops formed on the loop table 300 (hereinafter referred to as the initial loop amount) before the leveler 200 starts conveying the coil material 120. The loop sensor 321 is provided, for example, at a position (height) where it can detect the initial loop amount corresponding to the feed length of the feeder 400. Note that a plurality of loop sensors 321 may be provided at different positions.

[0028] The control unit 260 can determine whether or not a loop exists at the position of the loop sensor 321 by monitoring the level of the signal output from the loop sensor 321. Hereinafter, the determination by the control unit 260 of the existence of a loop in the coil material 120 based on the detection result of the loop sensor 321 may be expressed as "a loop has been detected," and the determination of the absence of a loop may be expressed as "no loop detected." When the loop sensor 321 detects a loop, the control unit 260 determines that the initial loop retention amount is equal to or greater than the feed length, and when the loop sensor 321 does not detect a loop, the control unit 260 determines that the initial loop retention amount is less than the feed length. Note that a plurality of loop sensors 321 may be arranged at different positions to more accurately determine the initial loop retention amount.

[0029] The control unit 360 controls the motor 380 based on the detection results of sensors (not shown) and the like of the loop table 300 in accordance with various programs stored in the memory unit 370, thereby controlling the motor 380 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 cause the table 310 to follow the loop. Furthermore, the control unit 360 notifies the control units of other devices in the press system 1 to perform predetermined control based on the detection results of the loop sensor 321.

[0030] The motor 380 is, for example, a geared motor, and raises the table 310 so that the table 310 can follow the loop.

[0031] <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 an R guide 405, a feed roll 410, a control unit 440, a memory unit 450, a cylinder 460, and a motor 470.

[0032] The feed rolls 410 function as a feeding means for feeding the coil material 120 to the press device 500. The feed rolls 410 are a pair of upper and lower rolls that sandwich and transport the coil material 120 between the two rolls. 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 begins, the feed rolls 410 are closed 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 set according to the processing to be performed in the press device 500. The feed rolls 410 are open and release the coil material 120 while processing is being performed in the press device 500. Note that, taking into account all circumstances, it is also possible to set the feed rolls 410 to remain closed and grip the coil material 120.

[0033] Cylinder 460 switches between a closed state in which feed roll 410 clamps coil material 120 and an open state in which it does not clamp coil material 120. Motor 470 drives the rotation of feed roll 410. R guide 405 imparts a predetermined curvature to coil material 120 transported from loop table 300. Coil material 120 is fed along R guide 405 and is transported into feeder 400 without being bent.

[0034] The control unit 440 controls the cylinder 460 and the motor 470 in conjunction with other devices of the press system 1, thereby feeding the coil material 120 to the press device 500. The control unit 440 controls the rotation of the feed roll 410 by a known method using a detection means such as an encoder. Similarly, the control unit 440 controls the switching between the open state and the closed state of the feed roll 410 by a known method.

[0035] 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 may store, for example, a feed length and a feed speed associated with each process and / or die. The control unit 440 feeds out the coil material 120 at a predetermined feed length and a predetermined feed speed according to the process and / or die of the press device 500.

[0036] <Pressing equipment> The press apparatus 500 of FIGS. 1 and 2 will be described with reference to FIG. 3 as well. FIG. 3 is a schematic perspective view showing the configuration of the press apparatus 500 of this embodiment, e.g., an integral straight-side frame or C-frame type press apparatus 500. FIG. 3 also shows the conveying direction of the coil material 120, as well as the upstream (left), downstream (right), up-down, and front-rear directions (front and back) in the conveying direction. The press apparatus 500 includes 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 device 500 of this embodiment may be a progressive press device that performs progressive press working (hereinafter referred to as progressive working), in which case it has multiple working stages. Progressive working is also called transfer stamping, and the transfer press tool that constitutes it can be a single press die (upper and lower dies) or multiple press dies arranged in successive stations.

[0037] The drive motor 504 is, for example, a servo-controlled servo motor, and moves a mold 503 (described later) up and down while controlling the amount and direction of rotation via a transmission mechanism 506, a crankshaft 508, and a connecting rod 510. 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.

[0038] 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).

[0039] 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.

[0040] 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).

[0041] 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. 3, and hereinafter the transport direction of coil material 120 is also referred to as the left-right direction.

[0042] 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.

[0043] 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 strain on the left and right sides of the housing 502 may be detected separately, and the detected results may be added up to determine the total load. Note that in FIG. 3, the side on which the display unit 516 is located is the front side of the press device 500.

[0044] 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. The controller 514 in this embodiment also controls the press system 1 as a whole.

[0045] The controller 514 determines the start timing at which the leveler 200 starts conveying the coil material 120, based on the information about the press apparatus 500 and the information about the feeder 400 input from the input unit 518. The controller 514 also adds, to the determined start timing, a time corresponding to the initial loop amount formed in the loop table 300 before the leveler 200 starts conveying the coil material 120. The controller 514 also controls the leveler 200 to start conveying the coil material 120 at the determined start timing. The controller 514 also determines the speed at which the leveler 200 conveys the coil material 120, based on the information about the press apparatus 500 and the information about the feeder 400 input from the input unit 518, and controls the leveler 200 to convey the coil material 120 at the determined speed. These will be described later.

[0046] Furthermore, the control units and controllers of each device in the press system 1 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. Alternatively, a specific device may not have a control unit and may be controlled by the control unit of another device, as long as the press system 1 as a whole can control various operations. 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.

[0047] <Feed start angle and maximum feed angle> 4(a) is a diagram showing the feed start angle and the possible feed angle in this embodiment. In the press device 500, the slide 512 descends from the top dead center and processes the coil material 120 near the bottom dead center. The angle of the crankshaft 508 while the coil material 120 is being processed is defined as the processing angle θ1. Because the feeder 400 is stopped for a time corresponding to the processing angle θ1, the time corresponding to the processing angle θ1 is defined as the stop time Tstop.

[0048] The transport of the coil material 120 from the feeder 400 to the press device 500 begins when processing is completed. The rotation angle (angle of the crankshaft 508) when processing is completed is angle θs, for example, when the top dead center is used as the reference angle. The angle θs will be referred to as the feed start angle hereinafter. The transport of the coil material 120 by the feeder 400 begins at the feed start angle θs and is performed during a period when processing is not being performed in the press device 500. The period during which the coil material 120 can be transported from the feeder 400 to the press device 500 corresponds to the rotation angle (angle of the crankshaft 508) θ2 from the end of processing to the start of the next processing, and the angle θ2 is the available feed angle. The available feed angle θ2 is 360° minus the processing angle θ1 (θ2 = 360° - θ1). Hereinafter, the timing corresponding to the feed start angle θs will be referred to as the feed start timing ts_fed, and the time corresponding to the available feed angle θ2 will be referred to as the available feed time t_avl. Also, the time corresponding to one cycle (one rotation of the crankshaft 508) will be referred to as the cycle time t_cyc (=t_avl+Tstop).

[0049] <Feeder feed speed and feed length and leveler speed> FIG. 4(b) is a diagram showing the feed speed and feed length of the feeder 400 and the speed of the leveler 200. (i) is a graph showing the relationship between the feed speed and feed length of the feeder 400, with the horizontal axis representing time [sec] and the vertical axis representing the feed speed [m / min] of the feeder 400. The feed speed of the feeder 400 is generally expressed in millimeters per second, but is expressed in meters per minute to match the units with the line speed. (ii) is a graph showing the relationship between the speed [m / min] of the leveler 200 and the length of the coil material 120 transported by the leveler 200, with the horizontal axis representing time [sec] and the vertical axis representing the speed [m / min] of the leveler 200. (i) also shows the cycle time t_cyc, available feed time t_avl, stop time Tstop, and feed start timing ts_fed described in FIG. 4(a).

[0050] As shown in (i), the feeder 400 accelerates to a predetermined feed speed Vt during the available feed time t_avl, transports the coil material 120 at the predetermined feed speed Vt, and then decelerates to a speed of 0. The feeder 400 transports the coil material 120 of a feed length L during the available feed time t_avl. The area of ​​the trapezoid shown in (i) is the feed length L.

[0051] In this embodiment, the leveler 200 is controlled so as to transport, during the cycle time t_cyc, a length of the coil material 120 that is approximately equal to the feed length L that the feeder 400 transports during the available feed time t_avl. In other words, in this embodiment, the leveler 200 is controlled so that the area S of the rectangle in (ii) is approximately equal to the feed length L, which is the area of ​​the trapezoid in (i). Specifically, the leveler 200 is controlled so that the area S is approximately equal to the feed length L by starting transport of the coil material 120 from a feed start timing ts_str that is determined based on the feed length L and the line speed V.

[0052] <Cumulative feed amount of coil material> The feeder 400 of this embodiment effectively utilizes the available feed time t_avl from the timing when the feed start angle θs is exceeded in the press device 500. In other words, it uses the entire available feed time t_avl to transport the coil material 120 by the feed length L. This is to prevent a sudden change in the loop amount consumed by the feeder 400. The feeder 400 repeats this operation for each processing cycle. At this time, the cumulative feed length of the feeder 400 is as shown in FIG. 5(a). Hereinafter, the cumulative feed length of the feeder 400 is referred to as the cumulative feed amount S_fed. Hereinafter, FIG. 5(a) is a graph showing the cumulative feed amount S_fed of the coil material 120 transported by the feeder 400, with the horizontal axis representing time [sec] and the vertical axis representing the cumulative feed amount S_fed [mm].

[0053] When processing is started in the press system 1, the feeder 400 conveys the coil material 120 of the feed length L using the available feed time t_avl from timing t1 (feed start timing ts_fed) corresponding to the feed start angle θs. During the stop time Tstop from timing t2, when the conveyance of the coil material 120 of the feed length L is completed, to timing t3, when the next feed start angle θs is reached, the press device 500 processes the coil material 120, and the feeder 400 stops conveying the coil material 120. At timing t3, the feeder 400 conveys the coil material 120 of the feed length L by timing t4 using the available feed time t_avl. The feeder 400 repeats this operation, so the graph shown in FIG. 5(a) has a stepped shape.

[0054] The leveler 200 of this embodiment continuously conveys the coil material 120 at a line speed V determined based on the feed length L of the feeder 400 and the rotation speed of the press device 500. Therefore, in this embodiment, the leveler 200 accelerates from a speed of 0 for an acceleration time ta_str, and after reaching the line speed V, conveys the coil material 120 at a constant line speed V. The acceleration time ta_str is determined based on the line speed V and the characteristics of the motor 290 of the leveler 200. FIG. 5(b) is a graph showing the cumulative feed amount S_str of the coil material 120 conveyed by the leveler 200, with the horizontal axis representing time [sec] and the vertical axis representing the cumulative feed amount S_str [mm]. Maintaining a constant speed at which the leveler 200 conveys the coil material 120 does not reduce the accuracy of straightening the coil curl of the coil material 120, and minimizes the number of accelerations and decelerations, which is advantageous from the viewpoint of energy conservation.

[0055] <Loop holdings> FIG. 6 is a graph showing the change in loop amount caused by the speed difference between the conventional feeder 400 and the leveler 200. In FIG. 6, the loop reserve amount is shown by a solid line, the cumulative feed amount S_fed of the feeder 400 is shown by a dashed line, and the cumulative feed amount S_str of the leveler 200 is shown by a dashed line. The loop amount is the difference between the cumulative feed amount S_str of the leveler 200 and the cumulative feed amount S_fed of the feeder 400, and is hereinafter also referred to as the loop reserve amount. Specifically, the loop reserve amount is the value obtained by subtracting the cumulative feed amount S_fed of the feeder 400 from the cumulative feed amount S_str of the leveler 200. When the loop reserve amount is positive, the loop reserve amount is sufficient, and when the loop reserve amount is negative, the loop reserve amount is insufficient. The loop reserve amount changes depending on the feed start timing ts_str of the leveler 200. Fig. 6(a) shows a case where the feed start timing ts_str of the leveler 200 is earlier than the feed start timing ts_fed of the feeder 400, and Fig. 6(b) shows a case where the feed start timing ts_str of the leveler 200 is approximately the same as the feed start timing ts_fed of the feeder 400. In both Figs. 6(a) and 6(b), the horizontal axis shows time [sec] and the vertical axis shows the cumulative feed amount or the loop reserve amount [mm]. Note that in both cases, the initial loop reserve amount is set to 0.

[0056] In conventional control, the leveler 200 starts conveying the coil material 120 after the loop amount in the loop table 300 decreases or becomes zero. Therefore, as shown in FIG. 6(b), the loop inventory becomes negative and insufficient. To prevent the loop inventory from becoming negative as shown in FIG. 6(b), the initial loop inventory must be increased, which increases the overall line length. On the other hand, if the feed start timing ts_str of the leveler 200 is advanced as shown in FIG. 6(a), the loop inventory becomes positive and is not insufficient, but the loop inventory becomes excessive. Therefore, control is required to stop the leveler 200 in order to reduce the excessive loop inventory. Furthermore, control is also required to start the stopped leveler 200, which can result in the next coil material 120 not being conveyed in time or the coil material 120 becoming bent.

[0057] (Bending of the loop) FIG. 7(a) is a diagram illustrating the bending of the loop formed between the R guide 205 of the leveler 200 and the R guide 405 of the feeder 400, and also shows the conveying direction of the coil material 120. To shorten the overall line length of the press system 1, the distance between the R guide 205 and the R guide 405 may be shortened. In such a case, the timing ts_str at which the leveler 200 starts feeding the coil material 120 is early, resulting in a large loop retention, which reduces the radius of curvature at both guides and causes a bending tendency in the coil material 120. The coil material 120A shown by the dashed line in FIG. 7(a) has a larger loop retention than the coil material 120 shown by the solid line, resulting in a bending tendency at the contact points with both guides and near the lowest point of the loop.

[0058] <Settings screen> A setting screen for inputting parameters into the press system 1 to control the feed start timing ts_str of the leveler 200 of this embodiment will be described. FIG. 7(b) is a diagram showing a setting screen for determining the feed start timing ts_str of the leveler 200. Information required for automatically setting the feed start timing ts_str of the leveler 200 to minimize the loop amount in the loop table 300 will be described. The following description will be given of an example in which the setting screen is displayed on the display unit 516 of the press apparatus 500 and various parameters are input using the input unit 518. However, the press system 1 may be provided with a separate display means and input means, and various parameters may be input using the display means and input means. Alternatively, the leveler 200 or the feeder 400 may have a display means and input means, and various parameters may be input using the display means and input means.

[0059] The setting screen 600 displayed on the display unit 516 displays, for example, a "Leveler Start Timing / Line Speed ​​Automatic Setting Screen." The setting screen 600 includes an input parameter input field 610 and an input key group 620. Information about the press 500 and information about the feeder 400 are entered into the input parameter input field 610 (input process). The information about the press 500 includes the rotation speed spm [spm], feed start angle θs [°], and available feed angle θ2 [°] of the press 500. The information about the feeder 400 includes the feed length L [mm]. The line speed V can be calculated from the rotation speed spm and feed length L of the press 500. The feed start timing ts_fed can be calculated from the feed start angle θs, and the available feed time t_avl can be calculated from the available feed angle θ2. The controller 514 uses these values ​​to determine the feed start timing ts_str of the leveler 200 , and sets set values ​​including the feed start timing ts_str and the line speed V in the controller 240 of the leveler 200 via the control unit 260 of the leveler 200 .

[0060] The input key group 620 is used when the worker inputs information. The input key group 620 includes, for example, numeric keys, a delete key (DEL), a clear key (AC), an input key (ENT), etc., and is used to input, delete, etc. information. The input key group 620 is included in the input unit 518.

[0061] <Leveler start timing> The controller 240 determines control information for controlling the leveler 200 so that the leveler 200 conveys the conveyance amount of coil material during the cycle time based on the information about the press device 500 and the information about the feeder 400 input from the input unit 518. Here, the conveyance amount is the amount of coil material conveyed during the cycle time. Leveler 200 is the amount of conveyance of the coil material 120. The control information includes the start timing at which the leveler 200 starts conveying the coil material 120 and the speed (maximum speed, for example, line speed) at which the leveler 200 conveys the coil material 120. How to determine the start timing and line speed will be described below.

[0062] (When the initial loop capacity is 0) When the initial loop reserve amount is 0, the feed start timing ts_str of the leveler 200 is advanced so that the loop reserve amount does not become negative. Note that in the following explanation, the following symbols are used, including the symbols used in the explanations so far. Leveller 200 acceleration time [s]:ta_str Accumulative feed rate of Leveler 200 [mm]:S_str Cumulative feed amount of Feeder 400 [mm]: S_fed Leveler 200 feed start timing [s]: ts_str Feeder 400 feed start timing [s]: ts_fed Feeder 400's available feeding time [s]: t_avl Rotation speed of press device 500 [spm]:spm Feeder 400 feed length [mm]: L Cycle time [s]: t_cyc=60 / spm Line speed [m / min]: V = L × spm / 1000

[0063] The cumulative feed amount S_str of the leveler 200 when the leveler 200 starts operating, accelerates, and reaches the line speed V is expressed by the following formula (1-1). S_str=V×1000 / 60×ta_str / 2 (1-1) The number of feeds by the feeder 400 that exceeds the cumulative feed amount S_str of the leveler 200 calculated by the formula (1-1) is expressed by the following formula (1-2): where decimals are rounded up. S_str / L (1-2) If the number of feeds calculated by equation (1-2) is N (the integer value obtained by rounding up the decimal point of S_str / L), the cumulative feed amount S_fed of feeder 400 when the Nth transport of coil material 120 in feeder 400 is completed is expressed by the following equation (1-3). S_fed=N×L (1-3)

[0064] The time te_fed from when the feeder 400 starts operating until the Nth feeding is completed is expressed by the following formula (1-4). te_fed=(N-1)×t_cyc+t_avl (1-4) The time te_str from the feed start timing ts_str at which the leveler 200 reaches the same cumulative feed amount S_str is expressed by the following equation (1-5). te_str=ta_str+ (S_fed-S_str) / (V×1000 / 60) (1-5) The start time td of the leveler 200 relative to the feed start timing ts_fed of the feeder 400 is calculated by the following equation (1-6). td=te_fed-te_str (1-6)

[0065] If the start time td is negative, the leveler 200 starts operating before the feeder 400, and if the start time td is positive, the leveler 200 starts operating after the feeder 400. That is, the feeding start timing ts_str is calculated by the following equation (1-7) (calculation step). ts_str=ts_fed+td (1-7)

[0066] FIG. 8 shows the change in the loop stock amount when the feed start timing ts_str of the leveler 200 of this embodiment is controlled. FIG. 8(a) is a graph showing the case where the initial loop stock amount is 0, and the legend is the same as in FIG. 6. In FIG. 8(a), the horizontal axis represents time [sec], and the vertical axis represents the cumulative feed amounts S_fed and S_str and the loop stock amount [mm]. The feed length L is, for example, 100 mm. In the example of FIG. 8(a), the start time td is negative, and the feed start timing ts_str of the leveler 200 precedes the feed start timing ts_fed of the feeder 400. Note that in the graph of FIG. 8(a), the start timing ts_tsr of the leveler 200 is earlier than the reference (time 0) used for timing control of the entire press system 1. By starting the leveler 200 before the feeder 400, the loop stock amount can be reduced to a minimum of approximately 0 mm and a maximum of approximately 50 mm.

[0067] It should be noted that the maximum speed of the leveler 200 may differ from the line speed V. When the maximum speed of the leveler 200 differs from the line speed V, the acceleration time ta_str of the leveler 200 may be changed using the ratio between the maximum speed and the line speed V. The controller 514 sets the line speed V (or the maximum speed) and the calculated feed start timing ts_str as set values ​​in the controller 240 via the control unit 260 of the leveler 200, and controls the leveler 200. Even when the start time td of the leveler 200 is negative, it is possible to control it in the case of the press system 1 of this embodiment, which is controlled integrally with the press device 500.

[0068] (Application example) In the press system 1, adjustment of the die 503 is performed before processing begins. At this time, the feeder 400 transports the coil material 120 by the feed length L to adjust the die 503. When the feed speed Vt and acceleration / deceleration time of the feeder 400 during adjustment are controlled to be the same as those of the leveler 200, and control is performed so that the feeder 400 and the leveler 200 start approximately simultaneously, the initial loop inventory may be set to the minimum initial loop inventory. Here, the minimum initial loop inventory is, for example, an inventory amount that does not cause tension on the coil material 120 between the leveler 200 and the feeder 400. The feed start timing ts_str of the leveler 200 may be set so that the minimum value of change in the loop inventory during processing by the press system 1 during adjustment is, for example, 0 mm, and the control of FIG. 8(a) described above may be applied.

[0069] In this way, the feed start timing ts_str can be set so that the cumulative feed amount S_str of the leveller 200 and the cumulative feed amount S_fed of the feeder 400 are approximately the same when the feeder 400 has completed transporting the coil material 120 by the feed length L after the leveller 200 has reached the line speed V.

[0070] (When the initial loop length is approximately equal to the feed length) If the initial loop holding amount is not 0, the start timing of the leveler 200 can be delayed by the amount of the initial loop holding amount. For example, the start timing of the leveler 200 is delayed until the difference between the cumulative feed amount S_fed of the feeder 400 and the cumulative feed amount S_str of the leveler 200 becomes the initial loop holding amount. Initial loop length [mm]:m (feed length L of Feeder 400) Then, the start time td can be calculated by the following equation (2-1). td=te_fed-te_str+m / (V×1000 / 60) (2-1) The start time td calculated by equation (2-1) is input into the above-mentioned equation (1-7) to calculate the feed start timing ts_str of the leveler 200. In this way, the controller 514 advances the start timing ts_str as the initial loop retention amount decreases. In other words, the controller 514 delays the feed start timing ts_str as the initial loop retention amount increases.

[0071] FIG. 8(b) is a graph showing a case where the initial loop reserve amount m is equal to the feed length L, and the legend is the same as in FIG. 6. In FIG. 8(a), the horizontal axis represents time [sec], and the vertical axis represents cumulative feed amounts S_fed, S_str, and loop reserve amount [mm]. The feed length L is, for example, 100 mm. In the example of FIG. 8(b), a time equivalent to the initial loop reserve amount m is added to the start time td, so that the feed start timing ts_str of the leveler 200 is approximately simultaneous with the feed start timing ts_fed of the feeder 400. When the initial loop reserve amount m is approximately the same as the feed length L, even if the leveler 200 and the feeder 400 are started approximately simultaneously, the loop reserve amount can be a minimum of approximately 0 mm and a maximum of approximately 50 mm.

[0072] (Application example) When adjusting the die 503 in the press system 1, there are cases where the speed control when the feeder 400 conveys the coil material 120 with a feed length L must be the same as the speed control during continuous operation of the press system 1. In this case, an initial loop reserve amount m approximately equal to the feed length L for one pass is required. In this case, the feed start timing ts_str of the leveler 200 is determined so that the minimum value of the change in the loop reserve amount during processing is equal to the feed length L for one pass. In this case, it is sufficient to make the difference between the cumulative feed amount S_str of the leveler 200 at the time when the feeder 400 has completed feeding after the leveler 200 has reached the line speed V and the cumulative feed amount S_fed of the feeder 400 approximately equal to the feed length L.

[0073] As described above, according to this embodiment, it is possible to provide a press system and a method for controlling a press system that can make the amount of loop formed upstream of the feeder in the conveying direction of the coil material as small as possible.

[0074] 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 and ideas. In the above-described embodiment, the press system 1 is described as being under integrated control, but the present invention is not limited to this. For example, the start time td and the feed start timing ts_str of the leveler 200 determined by the control means may be displayed on the display unit. The operator may set a cam switch of the leveler 200 so that the feed start timing ts_str displayed on the display unit is the same.

[0075] [Objective 1] The press system of the present invention comprises: a straightening device that conveys the coil material while straightening the curl 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 control means for controlling the straightening device, the pressing device, and the feeding device; A press system comprising: an input unit into which information about the press device and information about the feed device are input; The control means determines the transport amount of the coil material that the feed device will transport during a cycle time, which is a time period corresponding to the rotation speed of the press device, based on the information about the press device and the information about the feed device input from the input unit, and determines control information for controlling the straightening device so that the straightening device transports the transport amount of the coil material during the cycle time.

[0076] [Objective 2] The control information may include a start timing at which the straightening device starts conveying the coil material.

[0077] [Objective 3] The control information may include a speed at which the straightening device conveys the coil material.

[0078] [Objective 4] The information about the press device may include the number of rotations of the press device, the rotation angle at which processing by the press device ends, and the rotation angle from the end of processing by the press device to the start of the next processing.

[0079] [Objective 5] The information about the feeding device may include the predetermined feeding length.

[0080] [Objective 6] a loop forming device that bends the coil material between the straightening device and the feeding device to form a loop, The control means may add, to the determined start timing, a time corresponding to an initial loop quantity, which is the quantity of loops formed in the loop forming device before the straightening device starts transporting the coil material.

[0081] [Objective 7] The control means may advance the start timing as the initial loop holding amount decreases.

[0082] [Objective 8] The method for controlling a press system of the present invention includes: A control method for a press system including a straightening device that conveys a coil material while straightening the coil material to remove any curling of the coil material, a press device that processes the coil material, a feed device that feeds the coil material to the press device at a predetermined feed speed by a predetermined feed length, and control means that controls the straightening device, the press device, and the feed device, the press system includes an input unit into which information about the press device and information about the feed device are input; an input step of inputting information about the press device and information about the feed device into the input unit; a calculation step in which the control means calculates a transport amount of the coil material to be transported by the transport device during a cycle time, which is a time corresponding to the number of rotations of the press device, based on information related to the press device and information related to the transport device input from the input unit, and calculates control information for controlling the straightening device so that the straightening device transports the transport amount of the coil material during the cycle time; Equipped with. [Explanation of symbols]

[0083] 1 Press System 10 Floor 100 Uncoiler 110 Mandrel 120, 120A coil material 130 Control Unit 140 Drive Unit 200 Leveller 205 R Guide 220 Entrance Roll 230 Work Roll 240 Controller 250 Brake Roll 260 Control Unit 270 Storage section 280 cylinders 290 Motor 300 Loop Table 310 Table 315 Encoder 321 Loop Sensor 360 Control Unit 370 Storage section 380 Motor 400 Feeder 405 R Guide 410 Feed Roll 440 Control Unit 450 Storage section 460 cylinders 470 Motor 500 Press Equipment 502 Case 503 Mold 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 600 Settings screen 610 Input parameter input field 620 input keys

Claims

1. a straightening device that conveys the coil material while straightening the curl 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 control means for controlling the straightening device, the pressing device, and the feeding device; A press system comprising: an input unit into which information about the press device and information about the feed device are input; The control means calculates a transport amount of the coil material to be transported by the straightening device during a cycle time, which is a time period corresponding to the rotation speed of the press device, based on information related to the press device and information related to the feed device input from the input unit, and calculates control information for controlling the straightening device so that the straightening device transports the transport amount of the coil material during the cycle time, the control information including a start timing at which the straightening device starts transporting the coil material.

2. The press system according to claim 1 , wherein the control information includes a speed at which the straightening device conveys the coil material.

3. 3. The press system according to claim 1, wherein the information about the press device includes a rotation speed of the press device, a rotation angle at which processing by the press device ends, and a rotation angle from the end of processing by the press device to the start of a next processing.

4. The press system according to claim 1 or 2, wherein the information about the feed device includes the predetermined feed length.

5. a loop forming device that bends the coil material between the straightening device and the feeding device to form a loop, 5. The press system according to claim 3, wherein the control means adds a time corresponding to an initial loop quantity, which is the quantity of loops formed in the loop forming device, to the calculated start timing before starting the conveyance of the coil material by the straightening device.

6. The press system according to claim 5 , wherein the control means advances the start timing as the initial loop holding amount decreases.

7. A control method for a press system including a straightening device that conveys a coil material while straightening the coil material to remove any curling of the coil material, a press device that processes the coil material, a feed device that feeds the coil material to the press device at a predetermined feed speed by a predetermined feed length, and control means that controls the straightening device, the press device, and the feed device, the press system includes an input unit into which information about the press device and information about the feed device are input; an input step of inputting information about the press device and information about the feed device into the input unit; a calculation step in which the control means calculates a transport amount of the coil material to be transported by the straightening device during a cycle time, which is a time corresponding to the rotation speed of the press device, based on information related to the press device and information related to the feed device input from the input unit, and calculates control information to control the straightening device so that the straightening device transports the transport amount of the coil material during the cycle time, the control information including a start timing at which the straightening device starts transporting the coil material; A method for controlling a press system, comprising:

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