Handling support image display method and press brake control device

Abstract

As the bending process progresses on the press brake, the necessary images are displayed in a timely manner, allowing the worker to perform the bending process efficiently without having to manually switch between them. [Solution] When the NC device 10 detects that bending of the workpiece W has begun in the press brake 100, it displays on the display device 30 a handling image showing how the workpiece W is being held by the operator of the press brake 100; when it detects that the workpiece W has been inserted into the press brake 100, it displays on the display device 30 a workpiece image showing the workpiece W pressed against the butt 42, superimposed on an image of the butt 42 and the workpiece W; and when it detects that the workpiece W has been removed from the press brake 100, it displays on the display device 30 a change support image showing the procedure for changing from the way the workpiece W is being held in the current process to the way the workpiece W is being held in the next process.

Description

[Technical Field]

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

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

[0003] [Patent Document 1] Special Publication No. 2021-534975 Summary of the Invention [Problem to be solved by the invention]

[0004] In bending processes performed with a press brake, the necessary information changes constantly over a short period of time, so the necessary information must be displayed to the worker in a timely manner as the bending process progresses. However, with the conventional part-forming method described above, the machine is unable to recognize the progress of the bending process, so the worker must manually switch the display screen to obtain the necessary information. Therefore, the worker must manually switch the display screen one by one, which creates the problem of being unable to perform the bending process efficiently. [Means for solving the problem]

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

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

[0007] According to the method for displaying handling support images in one or more embodiments, as the bending process progresses in the press brake, the necessary images can be displayed in a timely manner without the operator having to manually switch between them, allowing the bending process to be performed efficiently. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a perspective view showing the structure of a press brake according to one embodiment. [Figure 2] FIG. 2 is a block diagram showing the configuration of an NC device according to an embodiment. [Figure 3] FIG. 3 is a flowchart showing a processing procedure for displaying a handling support image by an NC device according to an embodiment. [Figure 4] FIG. 4 is a diagram illustrating an example of a handling image displayed by the NC device according to an embodiment. [Figure 5] FIG. 5 is a diagram illustrating an example of a superimposed image displayed by an NC device according to an embodiment. [Figure 6] FIG. 6 is a diagram illustrating an example of a change support image displayed by the NC device according to an embodiment. DETAILED DESCRIPTION OF THE INVENTION

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

[0010] The press brake 100 comprises an upper table 1, a lower table 3, and left and right side plates 5R and 5L. An upper die holder 2 is attached to the upper table 1, and a lower die holder 4 is attached to the lower table 3. The upper table 1 is configured to move up and down by hydraulic cylinders 6L and 6R provided on the left and right. A punch P, which is an upper die, is attached to the upper die holder 2, and a die D, which is a lower die, is attached to the lower die holder 4.

[0011] On the rear side of the lower table 3, there is a processing area 40 where the workpiece W is processed by the press brake 100, and a plurality of butts 42 are arranged which move in the left-right direction along a backgauge carriage 41. The butts 42 are configured to move in the height direction and the front-rear direction as well.

[0012] The worker places the workpiece W, which is the sheet metal to be processed, on the die D. Before bending the workpiece W, the butt 42 moves to the processing position according to the processing program, so the worker places the workpiece W on the die D so that the rear end of the workpiece W presses against the butt 42.

[0013] An operation pendant 7 is attached via an arm to the left side of the press brake 100, and the operation pendant 7 is provided with a display unit 71 and a plurality of operation buttons including a start button 72. The operation pendant 7 is connected to an NC device 10. In addition, a foot switch 8 that raises and lowers the upper table 1 is connected to the NC device 10.

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

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

[0016] Specifically, when the NC device 10 detects that bending of the workpiece W has started in the press brake 100, it displays on the display device 30 a handling image showing how the workpiece W is being held by the operator of the press brake 100. Next, when the NC device 10 detects that the workpiece W has been inserted into the press brake 100, it displays on the display device 30 a workpiece image showing the workpiece W pressed against the butt 42 of the press brake 100, superimposed on a captured image of the butt 42. Then, when the NC device 10 detects that the workpiece W has been removed from the press brake 100, it displays on the display device 30 a change support image showing the procedure for changing from the way the workpiece W is being held in the current process to the way the workpiece W is being held in the next process.

[0017] The camera 20 is attached to a connecting bar 51 that connects the side plate 5R and the side plate 5L, and is disposed on the rear side of the upper table 1. The camera 20 captures an image of the machining area 40, which includes the butt 42 and the workpiece W, from above, and outputs the captured image to the NC device 10. The machining area 40 is an area where the workpiece W is machined by the press brake 100, and is an area that includes the right end to the left end of the lower table 3.

[0018] The display device 30 is a tablet terminal that displays images to assist in handling the workpiece W, and is installed on the upper table 1 of the press brake 100. Therefore, the display device 30 is installed in a position where it can be seen by the worker who presses the workpiece W against the butt 42.

[0019] The processing program database 50 stores processing programs and also stores information necessary for controlling the bending process executed by the press brake 100. For example, information on the shape of the workpiece W, position information for placing the workpiece W, information on the butt 42 used in the bending process, coordinates for placing the butt 42, etc. are stored.

[0020] The processing program also records at least the position of the butt 42, the insertion direction and insertion position of the workpiece W, the position of the butt 42 against which the workpiece W is pressed, and the shape of the workpiece W for each bending process.

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

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

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

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

[0025] The NC device 10 is configured by a computer having a memory, a processor such as a CPU (Central Processing Unit), and various interfaces. The memory and various interfaces are connected to the processor via a bus. By having the processor execute a program stored in the memory, the NC device 10 executes control to display an image that assists in handling the workpiece W on the display device 30.

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

[0027] In step S103, the processing control unit 12 determines whether or not bending of the workpiece W has started in the press brake 100. If the worker operates the start button 72 to start bending of the workpiece W, the process moves the butt 42 to the position of the first bending process and proceeds to step S105; if bending has not started, the process continues to determine whether or not bending has started.

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

[0029] Fig. 4 is a diagram showing an example of a handling image. As shown in Fig. 4, the handling image is a three-dimensional simulation image showing the workpiece W oriented in the direction in which it will be inserted into the press brake 100 and the position in which a worker holds the workpiece W. In Fig. 4, an image 31 of a hand is displayed in the position in which the worker holds the workpiece W, and an arrow 33 indicates the direction in which the workpiece W is inserted into the press brake 100.

[0030] In this way, when the start button 72 is operated, the image control unit 14 detects that bending of the workpiece W has started, and displays a handling image on the display device 30. Therefore, the operator only needs to operate the start button 72, and the handling image is automatically displayed, so that the operator can easily recognize the correct way to hold the workpiece W by looking at the displayed handling image.

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

[0032] However, it may be possible to determine whether the workpiece W has been inserted into the press brake 100 without using an image captured by the camera 20, by providing a sensor for detecting objects, such as a distance measuring sensor, at the stop 42. Furthermore, it may be possible to determine whether the workpiece W has been inserted into the press brake 100 by capturing an image of the worker's movements and estimating their posture and behavior using AI (artificial intelligence).

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

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

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

[0036] When the image control unit 14 acquires a captured image from the camera 20, it generates a superimposed image by superimposing the workpiece image 45 on the captured image and displays it on the display device 30. This allows the worker to accurately position the workpiece W at the processing position by inserting the workpiece W into the processing area 40 so that it overlaps the workpiece image 45.

[0037] In this way, the image control unit 14 detects that the workpiece W has been inserted into the press brake 100, and displays the superimposed image on the display device 30. Therefore, the worker does not need to manually switch, and the superimposed image is automatically displayed simply by inserting the workpiece W, so that by pressing the workpiece W against the butt 42 in accordance with the workpiece image 45, the workpiece W can be placed in the correct processing position.

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

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

[0040] However, as with the insertion of the workpiece W, it is possible to provide a sensor for detecting objects such as a distance sensor at the stop 42 without using the image from the camera 20, or to use AI to estimate the posture and behavior of the worker based on his or her movements.

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

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

[0043] In step S117, the processing control unit 12 determines whether there is a change between the way the workpiece is held in the current process and the way the workpiece is held in the next process, and if there is a change, proceeds to step S119, and if there is no change, returns to step S107.

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

[0045] Fig. 6 is a diagram showing an example of a change support image. As shown in Fig. 6, the change support image shows, in an animated image, a change in the way the workpiece W is held from the current process to the next process, and displays, in animation, an arrow 55 indicating the direction in which the workpiece W is to be rotated, as well as the change in the way the workpiece W is held from the current process to the next process.

[0046] In Figure 6, first, a workpiece W1 showing how to hold it in the current process and an image of a hand 56 showing the position in which the workpiece W1 is being held are displayed and remain stationary for about one second. Then, when the image of the hand 56 disappears, an arrow 55 indicating the direction in which to rotate the workpiece W1 appears, and an animation of the workpiece W1 rotating is played. The animation finally stops for about two seconds, displaying a workpiece W2 showing how to hold it in the next process and an image of a hand 58 showing the position in which the workpiece W2 is being held. The workpiece W2 in the next process is rotated 180° from the workpiece W1 in the current process, so the back side is visible on top.

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

[0048] Thereafter, the process returns to step S107, and the processes from step S107 to step S119 are repeatedly executed. When it is finally determined in step S115 that the bending process has been completed, the display process of the handling support image according to this embodiment ends.

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

[0050] In particular, with the NC device 10 according to this embodiment, once the operator operates the start button 72, all images are automatically displayed until the bending process is completed, so the operator does not need to manually switch the display screen one by one, and can perform the bending process efficiently.

[0051] Furthermore, in the NC device 10 according to this embodiment, the handling image shows the workpiece W oriented in the direction in which it will be inserted into the press brake 100 and the position in which the worker holds the workpiece W. This allows the worker to easily recognize the correct way to hold the workpiece W by looking at the handling image.

[0052] Furthermore, in the NC device 10 according to this embodiment, the workpiece image 45 indicates the shape of the workpiece W to be pressed against the butt 42 and the position of the butt 42 against which the workpiece W is pressed. This allows the operator to accurately position the workpiece W at the processing position by inserting the workpiece W into the processing area 40 so that it overlaps with the workpiece image 45.

[0053] Furthermore, in the NC device 10 according to this embodiment, the change support image displays a moving image of the change in the way the workpiece W is held from the way it is held in the current process to the way it is held in the next process, along with an arrow 55 indicating the direction in which to rotate the workpiece W. This allows the worker to easily change the way the workpiece W is held in the next process by changing the way it is held while looking at the displayed change support image.

[0054] Although the embodiments of the present invention have been described above, the descriptions and drawings that form part of this disclosure should not be understood to limit the present invention. Various alternative embodiments, examples, and operating techniques will become apparent to those skilled in the art from this disclosure. [Explanation of symbols]

[0055] 1 Upper table 2 Upper mold holder 3 Lower table 4 Lower mold holder 5L,5R side plate 6L, 6R hydraulic cylinder 7 Operation pendant 8 Footswitch 10 NC unit (control unit) 12 Processing control unit 14 Image control unit 20 Camera 30 Display device 31, 56, 58 Hand images 33, 55 Arrows 41 Backgauge carriage 42 End 45 Workpiece images 46a, 46b, 46c Stop position 50 Machining program database 51 Connecting bar 72 Start button 100 Press Brake D die P Punch W, W1, W2 Work

Claims

1. When it is detected that bending of the workpiece has started by the press brake, a handling image showing how the workpiece is being held by the operator of the press brake is displayed on a display device of the press brake; When it is detected that the workpiece has been inserted into the press brake, a workpiece image showing the workpiece pressed against the butt of the press brake is superimposed on a captured image of the butt and the workpiece, and is displayed on the display device; When it is detected that the workpiece has been removed from the press brake, a change support image showing a procedure for changing the way the workpiece is held in the current process to the way the workpiece is held in the next process is displayed on the display device. How to display handling assistance images.

2. The handling image shows the workpiece oriented in the direction in which it will be inserted into the press brake and the position in which the worker holds the workpiece. The method for displaying a handling assistance image according to claim 1 .

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

4. The change support image displays an arrow indicating the direction in which the workpiece is to be rotated, and a moving image of the change in the way the workpiece is held from the way it is held in the current process to the way it is held in the next process. The method for displaying a handling assistance image according to claim 1 .

5. When it is detected that bending of the workpiece has started by the press brake, a handling image showing how the workpiece is being held by the operator of the press brake is displayed on a display device of the press brake; When it is detected that the workpiece has been inserted into the press brake, a workpiece image showing the workpiece pressed against the butt of the press brake is superimposed on a captured image of the butt and the workpiece, and is displayed on the display device; When it is detected that the workpiece has been removed from the press brake, a change support image showing a procedure for changing the way the workpiece is held in the current process to the way the workpiece is held in the next process is displayed on the display device. Press brake control device.

Images