Correction processing device and container manufacturing method

Abstract

A technology is disclosed that can more reliably remove abnormal bulges in press-molded products with a container structure that has one side open than conventional technology. [Solution] The correction processing device 10A of this embodiment is intended to remove abnormal outward bulges of a pair of second side walls 92 that are wider than a pair of first side walls 91 of a press-formed product 90 having a container structure with one side open, and is equipped with a work support member 11 that supports the press-formed product 90, and a pair of pressing members 30 that press from the outside at least both lateral ends of the end of the second side wall 92 on the opening 94 side of the press-formed product 90 supported by the work support member 11.

Description

[Technical Field]

[0001] The present disclosure relates to a container manufacturing method for manufacturing a rectangular parallelepiped container by removing abnormal bulges in a press-molded product of a container structure, and a correction processing device that can be used in the manufacturing method. [Background technology]

[0002] In a press-formed product having a container structure with one open side, in which a pair of second side walls facing in a second direction are wider than a pair of first side walls facing in a first direction, an abnormal bulge may occur in the open ends of the pair of second side walls, in which the open ends bulge outward in an arc shape over the entire lateral direction. To eliminate such abnormal bulges, a conventional correction processing device is configured to insert a pair of pressing members into the press-formed product to push apart the pair of first side walls, thereby pulling the entire open ends of the pair of second side walls in the lateral direction (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2009-142851 A (Figure 4, paragraph

[0012] ) Summary of the Invention [Problem to be solved by the invention]

[0004] However, the above-mentioned conventional correction processing device was not able to sufficiently remove abnormal bulges. This application discloses a technology that can more reliably remove abnormal bulges in press-formed products with a container structure that has one open side than conventional methods. [Means for solving the problem]

[0005] A first aspect of the present disclosure, made to solve the above-mentioned problems, is a correction processing device for correcting a press-formed product having a container structure with one open side, including a bottom wall, an opening facing the bottom wall, a pair of first side walls facing each other in a first direction, and a pair of second side walls facing each other in a second direction perpendicular to the first direction and wider than the pair of first side walls, to remove abnormal outward bulging at the opening side ends of the pair of second side walls, the correction processing device comprising: a work support member that supports the press-formed product; and a pair of pressing members that press from the outside at least both lateral ends of the opening side ends of the second side walls of the press-formed product supported by the work support member.

[0006] A second aspect of the present disclosure is a method for manufacturing a container, the method comprising: a preparation process for preparing a press-molded product having an abnormality in which the opening-side ends of the pair of second side walls bulge outward; the press-molded product having a container structure with one side open, the container structure including a bottom wall, an opening facing the bottom wall, a pair of first side walls facing each other in a first direction, and a pair of second side walls facing each other in a second direction perpendicular to the first direction and having a wider width than the pair of first side walls; and a correction process for removing the abnormal bulge of the pair of second side walls of the press-molded product and processing it into a rectangular parallelepiped container, wherein in the correction process, at least both lateral ends of the opening-side ends of the second side walls of the press-molded product are pressed from the outside. [Effects of the Invention]

[0007] Abnormal bulging, which can occur in a press-formed product of a container structure with one open side, occurs in the form of an arc-shaped outward bulge at the opening-side end of a pair of second side walls, which are wider than the pair of first side walls, across the entire lateral direction. In other words, compared to a flat, normal second side wall without a bulge, the abnormal second side wall has its lateral end inclined outward and curved with a radius of curvature that decreases toward the lateral center. In contrast, the technology disclosed herein applies pressure from the outside to at least both lateral ends of the opening-side end of the second side wall. This eliminates the outward tilt of the lateral end of the abnormal second side wall, which was impossible with conventional technology, and more reliably eliminates the abnormal bulge of the second side wall than with conventional technology. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1A is a perspective view of a press-formed product before trimming, FIG. 1B is a perspective view of the press-formed product after trimming and before correction processing, and FIG. 1C is a perspective view of a container manufactured by correcting the press-formed product. [Figure 2] FIG. 2 is a side cross-sectional view of the correction processing device. [Figure 3] FIG. 3 is a front view of the correction processing device. [Figure 4] Figure 4 is a cross-sectional view of the correction processing device. [Figure 5] FIG. 5 is a partially cutaway perspective view of a work support member. [Figure 6] Figure 6 is a partially enlarged cross-sectional view of the work support member. [Figure 7] FIG. 7 is a side cross-sectional view of the correction processing device taken along the AA cross section of FIG. [Figure 8] FIG. 8 is a side cross-sectional view of the correction processing device during correction processing. [Figure 9] FIG. 9 is a cross-sectional view of the correction processing device during correction processing. [Figure 10] 10A to 10C are schematic diagrams of a slide drive mechanism. [Figure 11] FIG. 11 is a conceptual diagram showing the configuration of the second embodiment. [Figure 12] Figure 12 is a conceptual diagram of an image of a press-formed product set on a work support member. DETAILED DESCRIPTION OF THE INVENTION

[0009] [First embodiment] 1 to 10, a correction processing device 10A and a manufacturing method of a container 90C according to a first embodiment of the present disclosure will be described. FIG. 1B shows an example of a press-formed product 90 that requires correction processing by the correction processing device 10A (i.e., requires correction). The press-formed product 90 has a container structure, for example, a rectangular parallelepiped, with one side open. The press-formed product 90 has a bottom wall 93, an opening 94 facing the bottom wall 93, a pair of first side walls 91 facing each other in a first direction H1, and a pair of second side walls 92 facing each other in a second direction H2 perpendicular to the first direction H1. If a direction perpendicular to the first direction H1 and the second direction H2 is defined as a third direction H3, the bottom wall 93 has a flat plate shape perpendicular to the third direction H3. In addition, the bottom wall 93 is a rectangle that is longer in the first direction H1 than in the second direction H2, and a pair of second side walls 92 that bend at approximately right angles from a pair of long sides of the outer edge of the bottom wall 93 are wider than a pair of first side walls 91 that bend at approximately right angles from a pair of short sides of the outer edge of the bottom wall 93.

[0010] Here, in terms of design, the pair of first side walls 91 and the pair of second side walls 92 are flat, and the shape of a planar cross section of the press-formed product 90 perpendicular to the third direction H3 is rectangular in design at any position in the third direction H3. However, as highlighted in Fig. 1B , during the press-forming process of the press-formed product 90, the pair of second side walls 92 bulge outward, and the planar cross section of the press-formed product 90 becomes a substantially rectangular shape with a pair of long sides bulging outward, and the bulge of the pair of long sides is substantially zero at the end on the bottom wall 93 side and gradually increases with increasing distance from the bottom wall 93. In detail, the pair of long sides of the rectangular flat cross section of the press-molded product 90 in the portion where the pair of second side walls 92 bulge extend in a substantially straight line at the end closer to the short side (i.e., the lateral end of the pair of second side walls 92) and are inclined outward with respect to the opposing direction of the short sides (i.e., the first direction H1), becoming more rounded as they move away from the short sides (i.e., as they approach the lateral center of the second side walls 92), with the entire second side walls 92 curved so that the radius of curvature is smallest at the lateral center. The pair of first side walls 91 are flat or slightly curved inward.

[0011] Specifically, the press-formed product 90 is manufactured using a type of press, such as a transfer press (see, for example, Japanese Patent No. 6626234) and a trimming device (see, for example, Japanese Patent Nos. 5864072 and 5864073). The transfer press draws a circular or elliptical blank punched from a metal sheet multiple times, forming it into an elliptical cylindrical shape with a bottom at one end during the process. The transfer press then further draws the elliptical cylindrical press-formed product and, if necessary, irons it to form it into a rectangular cylindrical shape with a bottom at one end. As a result, the press-formed product 90A has a pair of second side walls 92 that bulge outward and an irregular shape with a non-flat open end, as shown in FIG. 1A . Therefore, the trimming device cuts off the upper end portions of the pair of first side walls 91 and the pair of second side walls 92 in the press-formed product 90A, thereby producing a press-formed product 90 having a flat opening end as shown in Fig. 1B. Then, the corrective processing device 10A of the present embodiment removes the bulges in the pair of second side walls 92 in the press-formed product 90, thereby producing a container 90C having a substantially flat pair of second side walls 92 as shown in Fig. 1C.

[0012] Note that the press-formed product 90 of this embodiment is made of, for example, aluminum, but the metal material of the press-formed product 90 is not limited to aluminum and may be made of, for example, iron, copper, or an alloy of iron, copper, or aluminum. Furthermore, the press-formed product 90 of this embodiment has, for example, a rectangular planar shape, but the planar shape is not limited to a rectangle as long as it has a pair of first side walls 91 opposing each other in a first direction H1 and a pair of second side walls 92 opposing each other in a second direction H2 perpendicular to the first side walls 91, and the second side walls 92 are wider than the first side walls 91. For example, the press-formed product 90 of this embodiment may have two pairs of flat third side surfaces at the four corners thereof that are inclined with respect to the first direction H1 and the second direction H2 and have a narrower width than the first side walls 91, so that the planar shape of the press-formed product 90 is octagonal, or the pair of first side walls 91 may be semicircular and the pair of second side walls 92 may be flat, so that the planar shape of the press-formed product 90 is what is called a track shape.

[0013] As shown in Figure 2, the correction processing device 10A includes, for example, a base portion 80, a work support member 11 that stands vertically upward from the upper surface of the base portion 80, a pair of pressing members 30 that are arranged opposite each other horizontally across the work support member 11, and a work holding device 19.

[0014] 3, the workpiece support member 11 stands up from a base portion 80 and has a structure that can be fitted inside a press-formed product 90. Below, the respective parts of the correction processing device 10A will be described assuming that the first direction H1, second direction H2, and third direction H3 of the press-formed product 90 fitted into the workpiece support member 11 correspond to the first direction H1, second direction H2, and third direction H3 in the correction processing device 10A. Furthermore, of the workpiece support member 11, the surfaces facing the pair of first side walls 91 of the fitted press-formed product 90 will be referred to as a pair of first side surfaces 21, and the surfaces facing the pair of second side walls 92 will be referred to as a pair of second side surfaces 22.

[0015] The workpiece support member 11 fits exactly inside the press-formed product 90 and is formed by removing a portion of a rectangular parallelepiped larger than the press-formed product 90 in the third direction H3, forming a structure that is symmetrical in the first direction H1 and the second direction H2. A side recess 12 is recessed into each second side surface 22 of the workpiece support member 11. The front shape of the side recess 12 is a rectangle whose width is slightly smaller than that of the second side surface 22. In the third direction H3, the upper end of the side recess 12 is located near the upper end of the second side surface 22, and the lower end of the side recess 12 is located at the lower end of the second side surface 22. As shown in FIG. 4, the side recess 12 has a pair of slopes 12A formed in a range extending from the outer edges of both lateral ends to a position near the center in the lateral direction, and a slope 12B (see FIG. 3) of the same width and slope as the slopes 12A is formed at the top of the side recess 12. The portion surrounded on three sides by the inclined surfaces 12A and 12B forms a flat bottom surface 12C parallel to the first direction H1 and the third direction H3. In this embodiment, the inclination angle θ1 (see FIG. 4) of the inclined surface 12A with respect to the first direction H1 is, for example, 10 to 15°, and the depth of the side recess 12 is, for example, 1 to 3 mm.

[0016] As shown in Fig. 3, a pair of end support portions 13 are formed on each second side surface 22 of the work support member 11 by slightly recessing the remaining portions on both sides of the side recess 12 in the range from a position near the lower end of the work support member 11 to a position near the lower center in the vertical direction (third direction H3) in the second direction H2. Furthermore, each of the pair of inclined surfaces 12A forms a band-shaped recessed surface 12D that is slightly recessed in a stepped manner in the second direction H2 further from the end support portions 13 in the vertically elongated band-shaped range adjacent to the pair of end support portions 13 (see Fig. 5). As shown in Fig. 3, these end support portions 13 and band-shaped recessed surfaces 12D overlap from the inside of the range from the end on the opening 94 side of the press-formed product 90 to a position near the end. Specifically, as shown in FIG. 6, the end support portion 13 has a width that overlaps the R-chamfered surface 92R between the first side wall 91 and the second side wall 92 of the press-formed product 90 and the lateral end position of the second side wall 92. The band-shaped recessed surface 12D has approximately the same width as the end support portion 13. Furthermore, as shown in FIG. 7, the step surface between the end support portion 13 and the outer surface of the second side surface 22 above it forms an arc-shaped surface 13R that is continuous with the outer surface of the second side surface 22. Although not shown, the step surface between the band-shaped recessed surface 12D and the slope 12A above it also forms an arc-shaped surface that is continuous with the slope 12A. In this embodiment, the recession amount W of the end support portion 13 relative to the second side surface 22 is 1 to 2 mm.

[0017] The area of ​​the work support member 11 excluding the side recesses 12 and the end support portions 13 constitutes a positioning fitting portion 15 (see FIG. 3 ) that three-dimensionally positions the press-formed product 90. In detail, the positioning fitting portion 15 is made up of an upper surface 23 of the work support member 11, a pair of first side surfaces 21, and a pair of second side surfaces 22, the portions of which are excluding the side recesses 12 and the end support portions 13. The pair of first side surfaces 21 of the positioning fitting portion 15 overlap with the pair of first side walls 91 of the press-formed product 90, the pair of second side surfaces 22 of the positioning fitting portion 15 overlap with the pair of second side walls 92 of the press-formed product 90, and the upper surface 23 of the positioning fitting portion 15 overlaps with the bottom wall 93 of the press-formed product 90, thereby positioning the press-formed product 90 in three directions: a first direction H1, a second direction H2, and a third direction H3.

[0018] As shown in FIG. 4 , a pair of knock holes 16 penetrating in the vertical direction (third direction H3) are provided near both ends in the longitudinal direction (first direction H1) of the work support member 11 in a planar cross section, and a vent hole 18 penetrating in the vertical direction is provided in the center. The pair of knock holes 16 and the vent hole 18 also penetrate the base portion 80, and a pair of knockout pins 17 are housed inside the pair of knock holes 16 so that they can move up and down. The pair of knockout pins 17 are driven up and down by, for example, a servo motor or air cylinder (not shown) as a drive source, and protrude upward from the work support member 11 as needed to push up and remove the press-formed product 90 from the work support member 11. The vent hole 18 also prevents air from being trapped between the work support member 11 and the press-formed product 90.

[0019] 2 shows a portion of the workpiece holding device 19. The workpiece holding device 19 includes, for example, a stand (not shown) fixed to the base portion 80 and installed so as to straddle the workpiece support member 11, an air cylinder (not shown) fixed to the stand and extending in the vertical direction, a rod 19R (shown in FIG. 2) extending downward from the air cylinder, and a holding member 19A fixed to the lower end of the rod 19R. The workpiece holding device 19 holds down a press-formed product 90 fitted to the workpiece support member 11 from above. When the press-formed product 90 is attached to or detached from the workpiece support member 11, the holding member 19A waits in an upper position where it does not interfere with the press-formed product 90.

[0020] As shown in Fig. 2, the pair of pressing members 30 are supported by a pair of slide guides 81 attached to the upper surface of the base portion 80 so as to be slidable in the second direction H2. The pair of pressing members 30 have a height that faces an area extending from the lower end of the press-formed product 90 fitted into the work support member 11 to a position close to the lower end. Furthermore, as shown in Fig. 4, the width of the pair of pressing members 30 in the first direction H1 is slightly larger than that of the press-formed product 90. The pair of pressing members 30 slide when power is received from a pair of slide drive mechanisms 83 (see Fig. 10A) and press a pair of second side walls 92 of the press-formed product 90 supported by the work support member 11.

[0021] 2, the pressing surface 31 of the pressing member 30 against the second side wall 92 includes a first pressing plane 31A that is perpendicular to the second direction H2 and a second pressing plane 31B that is located above the first pressing plane 31A and inclined so as to move away from the second side wall 92 as it moves away from the first pressing plane 31A, with a rounded chamfer formed between the first pressing plane 31A and the second pressing plane 31B. Also, above the pressing surface 31, an inclined plane 31C is provided that is inclined more sharply than the second pressing plane 31B.

[0022] Specifically, in the vertical direction (third direction H3), the lower end position of the first pressing plane 31A is located below the open end of the press-molded product 90, and as shown in Fig. 7, the upper end position of the first pressing plane 31A (in other words, the lower end position of the R-chamfer) is located at a first intermediate position P1, which is the vertical intermediate position of the end support portion 13. Furthermore, the upper end position of the second pressing plane 31B is located at a second intermediate position P2, which is spaced upward from the end support portion 13. In other words, the third intermediate position P3, which is the upper end position of the end support portion 13, is located midway in the vertical direction of the second pressing plane 31B.

[0023] The upper end position of the first pressing plane 31A is also the lower end position of the second pressing plane 31B, and is also the intersection position of the first pressing plane 31A and the second pressing plane 31B. The inclination angle θ2 of the second pressing plane 31B with respect to the plane extending from the first pressing plane 31A is, for example, 2 to 4 degrees.

[0024] 10A shows a slide drive mechanism 83 for driving the pressing member 30 to slide in the second direction H2. A slide drive mechanism 83 is provided for each pressing member 30, and the slide positions of the pair of pressing members 30 can be changed independently and arbitrarily. Specifically, the slide drive mechanism 83 includes a servo motor 88 with a reducer as a drive source, and a slider-crank mechanism 87 that converts the rotation output of the servo motor 88 into sliding movement of the slider 85 in the first direction H1. The slider 85 of the slider-crank mechanism 87 has an inclined surface 85A that is inclined with respect to the first direction H1 and the second direction H2, at a portion facing the pressing member 30. Meanwhile, a sliding contact member 84 having an inclined surface 84A that comes into face-to-face contact with the inclined surface 85A of the slider 85 is fixed to the pressing member 30. Furthermore, a pair of second opposing members 86B protrude from both sides of the pressing member 30 and face a pair of first opposing members 86A standing upright from the base portion 80 (see FIG. 2) in the second direction H2. Furthermore, a compression coil spring 86 is sandwiched between the first and second opposing members 86A, 86B, and the elastic force of the compression coil spring 86 urges the pressing member 30 in a direction away from the workpiece support member 11. A control unit 88A including a servo amplifier controls the rotational position of the servo motor 88, thereby controlling the sliding position of the pressing member 30 in the second direction H2.

[0025] The mechanism for driving the pressing member 30 may be any type. For example, a cam 70 may be used to convert the rotational output of a servo motor 88 into a sliding movement of the pressing member 30, as in a slide drive mechanism 83V shown in FIG. 10B. Specifically, in the slide drive mechanism 83V shown in FIG. 10B, for example, a frame 71 is fixed to the pressing member 30. The frame 71 has a rectangular frame shape that is longer in the first direction H1 than in the second direction H2. A circular cam 70 fits between a pair of long sides of the frame 71 and is rotated by the servo motor 88. The rotation axis of the cam 70 is positioned offset from the center of the cam 70 (i.e., the center of the circle). This configuration also allows the sliding position of the pressing member 30 to be controlled. Alternatively, a ball screw mechanism 72A may be used, as in a slide drive mechanism 83W shown in FIG. 10C. That is, for example, a structure may be adopted in which a ball nut 73 is attached to a bracket 74 fixed to the pressing member 30, and a ball screw 72 that screws into the ball nut 73 is fixed to a rotation output portion of a servo motor 88. Furthermore, although not shown, a rack and pinion mechanism may be used for the slide drive mechanism.

[0026] The configuration of the correction processing device 10A of this embodiment has been described above. Next, the effects of the correction processing device 10A will be described.

[0027] In order to set the press-formed product 90 on the work support member 11 of the correction processing device 10A, a pair of pressing members 30 are placed in a standby position away from the work support member 11, as shown in Fig. 2. Furthermore, the pressing member 19A of the work holding device 19 is placed in a standby position above the work support member 11, at a distance greater than the height of the press-formed product 90. Then, after the press-formed product 90 is fitted into the work support member 11 manually or by a robot or the like, the pressing member 19A is lowered and the bottom wall 93 of the press-formed product 90 is pressed against the upper surface 23 of the work support member 11. This completes the setting of the press-formed product 90 on the work support member 11.

[0028] In this state, each control unit 88A controls the pair of pressing members 30 to move toward a target movement position. The target movement position is determined experimentally so that the pair of pressing members 30 presses the pair of second side walls 92 of the press-formed product 90 to a suitable position, as will be described later. As a result, the pair of second side walls 92 of the press-formed product 90 that have an abnormal bulge are pressed by the pair of pressing members 30.

[0029] The abnormal bulge that may occur in the press-formed product 90 having a container structure with one open side occurs in the form of an arc-shaped outward bulge at the opening 94-side end of a pair of second side walls 92, which are wider than a pair of first side walls 91. That is, compared to a flat, normal second side wall 92 without a bulge, the abnormal second side wall 92 has its lateral ends tilted outward and curved such that the radius of curvature decreases toward the lateral center. In contrast, the correction processing device 10A of this embodiment presses at least both lateral ends of the opening 94-side end of the second side wall 92 from the outside, as shown in FIG. 9 . This eliminates the outward tilt of the lateral ends of the abnormal second side wall 92, which was impossible with conventional technology, and more reliably eliminates the abnormal bulge of the second side wall 92 than with conventional technology.

[0030] Furthermore, even if only the lateral end portion of the second side wall 92 is pressed, abnormal bulging of the second side wall 92 can be reduced compared to conventional methods. However, in the correction processing device 10A of this embodiment, as shown in FIG. 4, the intersection line L1 between the pressing surface 31 of each pressing member 30 and an imaginary planar cross section parallel to the lateral direction (first direction H1) of the second side wall 92 is a straight line, and as shown in FIG. 9, each pressing member 30 presses the entire lateral direction of the end portion of the second side wall 92 on the opening 94 side from the outside, thereby facilitating the removal of the bulge throughout and increasing the flatness of the second side wall 92.

[0031] In addition, in the third direction H3, the entire pair of pressing surfaces 31 of the pair of pressing members 30 may be flat, but in this embodiment, each pressing surface 31 has a shape that includes a first pressing plane 31A that is perpendicular to the second direction H2 and a second pressing plane 31B that is inclined with respect to the second direction H2, thereby preventing the occurrence of pressing marks at the boundary between the pressed and non-pressed portions of the second side wall 92.

[0032] Furthermore, each second side surface 22 of the workpiece support member 11 that supports the press-formed product 90 is provided with a pair of end support portions 13 that extend in the third direction H3 and overlap from the inside of both lateral end positions of the second side wall 92 of the press-formed product 90, and a side surface recess 12 that is recessed between the pair of end support portions 13. Therefore, when the second side wall 92 is pressed by the pressing member 30, both lateral end portions of the second side wall 92 are sandwiched between the pressing member 30 and the end support portions 13, effectively eliminating outward tilt of the lateral end portions of the second side wall 92 and effectively eliminating bulging of the second side wall 92. Furthermore, each side surface recess 12 is provided with a pair of inclined surfaces 12A that gradually deepen with increasing distance from the adjacent end support portions 13, thereby preventing sudden deformation of the second side wall 92 and suppressing the occurrence of pressing marks.

[0033] Furthermore, the end support portion 13 may have an outer surface flush with the positioning fitting portion 15, but in this embodiment, the end support portion 13 is recessed below the positioning fitting portion 15, so that both lateral ends of the second side wall 92 are more susceptible to pressure and deformation, thereby more effectively eliminating bulges in the second side wall 92. Furthermore, the step surface between the end support portion 13 and the positioning fitting portion 15 is an arc surface 13R that continues to the positioning fitting portion 15, so that the occurrence of pressure marks can be suppressed.

[0034] Next, a method for manufacturing a container 90C using the corrective processing device 10A will be described. In the manufacturing method for a container 90C of this embodiment, a plurality of press-formed products 90 are prepared as a preparation step using the transfer press and trimming device described above. In this embodiment, the shapes of the plurality of press-formed products 90 are substantially uniform, and the bulge amounts of a pair of second side walls 92 of the press-formed products 90 are substantially the same.

[0035] Furthermore, as a preparation step, some of the press-formed products 90 are selected as samples. These sample press-formed products 90 are then sequentially set on the work support member 11 of the correction processing device 10A, and correction processing is performed by pressing them with the pair of pressing members 30. At this time, the control unit 88A changes the movement target positions when moving the pair of pressing members 30 toward the press-formed product 90 for each press-formed product 90. In other words, the amount of pressure applied to the press-formed product 90 by the pair of pressing members 30 is experimentally changed for each press-formed product 90. The shape of a container 90C manufactured from the sample press-formed products 90 is then examined, and the movement target positions that result in a rectangular parallelepiped container 90C with the least amount of bulging and distortion are determined as the movement target positions to be used in manufacturing the press-formed product 90C.

[0036] Once the above preparation steps are completed, multiple press-formed products 90 other than the sample are sequentially set on the work support member 11 of the correction processing device 10A, and the control unit 88A performs position control so that the pair of pressing members 30 move to their target movement positions. As a result, the pair of pressing members 30 press the pair of second side walls 92 of the press-formed product 90, performing correction processing to suitably remove abnormal bulges in the press-formed product 90, and sequentially producing press-formed products 90C. In this way, according to the manufacturing method for a container 90C of this embodiment, it is possible to manufacture containers 90C in which abnormal bulges are removed more reliably than in the past.

[0037] [Second embodiment] As shown in Figure 11, in this embodiment, a measuring device 79 capable of measuring the amount of bulge of a pair of second side walls 92 of a press-formed product 90 set on a work support member 11 is added to the correction processing device 10A of the first embodiment, and a control unit 88A is configured to control the amount of pressure applied to the pair of second side walls 92 by the pair of pressing members 30 based on the measurement results by the measuring device 79.

[0038] Specifically, the measuring device 79 includes a camera 78 that captures an image of the end portion of the press-formed product 90 on the opening 94 side in a state where the press-formed product 90 is set on the work support member 11 from a first direction H1, and an image processing unit 77. Fig. 12 shows an example of an image G captured by the camera 78. The image processing unit 77 calculates the distance F between the end support portion 13 of the work support member 11 and the outer surface of the second side wall 92 of the press-formed product 90 in the image G as a substitute value for the amount of bulge of the second side wall 92.

[0039] The amount of bulge of the second side wall 92 is the distance between the peak of the bulge on the outer surface of the second side wall 92 when the second side wall 92 is bulging and the outer surface of the second side wall 92 when the second side wall 92 is not bulging at the end of the opening 94 of the press-molded product 90, and can be determined by subtracting the thickness of the second side wall 92 and the amount of recession from the outer surface of the positioning fitting portion 15 of the end support portion 13 of the work support member 11 from the above-mentioned distance F.

[0040] A relational expression or a data table of suitable target movement positions of the pressing members 30 relative to the distance F is stored in the memory of each control unit 88A of the pair of slide drive mechanisms 83 for the pair of pressing members 30. The relational expression or the like was obtained experimentally by changing the target movement positions for various press-formed products 90 having different distances F. The relational expression and the data table may be obtained by simulation or theoretically.

[0041] When each control unit 88A acquires the measurement results of the pair of second side walls 92 of the press-formed product 90 set on the work support member 11, it determines a movement target position from the above-mentioned relational expressions, etc., and moves the pressing member 30 toward the press-formed product 90 using the movement target position. As a result, as in the first embodiment, abnormal bulges are removed from the press-formed product 90, and a container 90C is manufactured. According to this embodiment, it is possible to deal with variations in the amount of bulge of the second side walls 92 of the press-formed product 90.

[0042] [Other embodiments] In the above embodiment, the control unit 88A controls the position of the pressing member 30, but a configuration may also be adopted in which the control unit 88A controls the pressing force of the pressing member 30 against the second side wall 92. Specifically, the control unit 88A may control the driving current applied to the servo motor 88 to a target current value, thereby controlling the pressing force of the pressing member 30 to be the target pressing force.

[0043] Furthermore, the control unit 88A may be configured not to perform position control or force control on the pressing member 30, but to simply move the pressing member 30 toward the second side wall 92 to press it. In this case, the drive source is not limited to a servo motor, and may be, for example, an air cylinder or a hydraulic cylinder.

[0044] In the above embodiment, the intersection line L1 between the pressing surface 31 of the pressing member 30 and an imaginary planar cross section of the second side wall 92 parallel to the lateral direction (first direction H1) is straight, and the pressing surface 31 presses the entire lateral portion of the second side wall 92 (see FIG. 4 ). However, depending on the lateral size and thickness of the second side wall 92, the intersection line L1 may be curved so as to protrude toward the second side wall 92 or curved away from the second side wall 92. Alternatively, the intersection line L1 may be bent in a crank shape so that the pressing surface 31 presses only both lateral ends of the second side wall 92.

[0045] <Additional Notes> The following describes the group of features extracted from the above embodiment, while indicating, as necessary, the effects, etc. Note that, for ease of understanding, the symbols of specific configurations corresponding to the above embodiment are indicated in parentheses, etc. as appropriate, but these group of features are not limited to the specific configurations indicated in parentheses, etc.

[0046] [Feature 1] The press-formed product (90) has a container structure with one open side, and includes a bottom wall (93), an opening (94) facing the bottom wall (93), a pair of first side walls (91) facing each other in a first direction (H1), and a pair of second side walls (92) facing each other in a second direction (H2) perpendicular to the first direction (H1) and having a width wider than that of the pair of first side walls (91). The press-formed product (90) is subjected to correction processing to form the opening (94) side ends of the pair of second side walls (92). A correction processing device (10A) for removing abnormal outward bulges in a portion, the correction processing device (10A) comprising: a work support member (11) that supports the press-formed product (90); and a pair of pressing members (30) that press from the outside at least both lateral ends of the end of the press-formed product (90) supported by the work support member (11) on the opening (94) side of the second side wall (92).

[0047] [Feature 2] The correction machining device (10A) according to Feature 1, wherein the pair of pressing members (30) press the entire lateral portion of the end portion of the second side wall (92) on the opening (94) side from outside.

[0048] [Feature 3] The correction processing device (10A) described in Feature 2, wherein an intersection line (L1) between a pair of pressing surfaces (31) of the pair of pressing members (30) that press the pair of second side walls (92) and an imaginary planar cross section parallel to the first direction (H1) is a straight line.

[0049] [Feature 4] When a direction perpendicular to the first direction (H1) and the second direction (H2) is defined as a third direction (H3), the pair of pressing surfaces (31) of the pair of pressing members (30) that press the pair of second side walls (92) include: a first pressing plane (31A) that faces a range from the end of the pair of second side walls (92) on the opening (94) side to a first intermediate position (P1) in the third direction (H3) and is perpendicular to the second direction (H2); and a second pressing plane (31B) that faces a range of the pair of second side walls (92) from the first intermediate position (P1) to a second intermediate position (P2) that is farther from the opening (94) and is inclined so as to move away from the pair of second side walls (92) as it moves away from the first pressing plane (31A).

[0050] [Feature 5] The correction processing device (10A) described in Feature 4, wherein the inclination angle (θ2) of the second pressing plane (31B) with respect to the plane extending from the first pressing plane (31A) is 2 to 4°, and the corner between the first pressing plane (31A) and the second pressing plane (31B) is R-chamfered.

[0051] [Feature 6] The work support member (11) is formed so as to be able to fit inside the press-formed product (90), and if a direction perpendicular to the first direction (H1) and the second direction (H2) is defined as a third direction (H3), the work support member (11) is provided with: two pairs of end support portions (13) extending in the third direction (H3) and overlapping from the inside at both lateral end positions of the pair of second side walls (92) of the press-formed product (90); a pair of side recesses (12) recessed between each pair of the end support portions (13) and facing the pair of second side walls (92); and a positioning fitting portion (15) overlapping the bottom wall (93), the pair of first side walls (91), and the pair of second side walls (92) so as to position the press-formed product (90) three-dimensionally.

[0052] [Feature 7] The correction processing device (10A) described in Feature 6 is configured such that the pair of pressing members (30) are formed to press at least the portions of both lateral end portions of the pair of second side walls (92) that overlap with the end support portions (13) from the inside and the portions that overlap with the side recesses (12).

[0053] [Feature 8] The correction processing device (10A) described in feature 6 or 7, wherein each of the side recesses (12) is provided with a pair of inclined surfaces (12A) that gradually become deeper as they move away from the adjacent end support portions (13) on both sides.

[0054] [Feature 9] 9. The corrective machining device (10A) according to Feature 8, wherein the pair of inclined surfaces (12A) have an inclination angle (θ1) of 10 to 15° with respect to the first direction (H1).

[0055] [Feature 10] 10. The corrective machining device (10A) according to any one of features 6 to 9, wherein the end support portion (13) is recessed from the positioning fitting portion (15).

[0056] [Feature 11] The correction processing device (10A) according to Feature 10, wherein the recess amount of the end support portion (13) from the positioning fitting portion (15) is 1 to 2 mm.

[0057] [Feature 12] The correction processing device (10A) according to feature 10 or 11, wherein the step surface between the end support portion (13) and the positioning fitting portion (15) is an arc surface (13R) that continues to the positioning fitting portion (15).

[0058] [Feature 13] The correction processing device (10A) according to any one of features 6 to 12, wherein the side recess (12) is larger in the third direction (H3) than the end support portion (13) and is formed to face the range from the end of the press-molded product (90) on the opening (94) side to a position closer to the bottom wall (93).

[0059] [Feature 14] The pair of pressing surfaces (31) of the pair of pressing members (30) that press the pair of second side walls (92) have a width equal to or greater than the width of the work support member (11), and an intersection line (L1) between an imaginary planar cross section parallel to the first direction (H1) and the pair of pressing surfaces (31) is a straight line. If a direction perpendicular to the first direction (H1) and the second direction (H2) is defined as a third direction (H3), the pair of pressing surfaces (31) have a width equal to or greater than the width of the work support member (11), and the pair of pressing surfaces (31) extend from the end of the pair of second side walls (92) on the opening (94) side in the third direction (H3). 14. The correction processing device (10A) according to any one of features 6 to 13, including: a first pressing plane (31A) facing a range of the pair of second side walls (92) from the first intermediate position (P1) to a first intermediate position (P1) of the opening (94) and perpendicular to the second direction (H2); and a second pressing plane (31B) facing a range of the pair of second side walls (92) from the first intermediate position (P1) to a second intermediate position (P2) further away from the opening (94) and inclining so as to move away from the pair of second side walls (92) as it moves away from the first pressing plane (31A).

[0060] [Feature 15] The correction processing device (10A) described in feature 14, wherein the end support portion (13) is recessed from the positioning fitting portion (15), and a step portion between the end support portion (13) and the positioning fitting portion (15) is located between the first intermediate position (P1) and the second intermediate position (P2).

[0061] [Feature 16] The correction processing device (10A) according to any one of features 1 to 15, further comprising: a measuring device (79) that measures the amount of bulge (W) of the pair of second side walls (92); and a control device (88A) that controls the amount of pressing by the pair of pressing members (30) against the pair of second side walls (92) based on the measurement results by the measuring device (79).

[0062] [Feature 17] A press-molded product (90) has a container structure with one side open, and includes a bottom wall (93), an opening (94) facing the bottom wall (93), a pair of first side walls (91) facing each other in a first direction (H1), and a pair of second side walls (92) facing each other in a second direction (H2) perpendicular to the first direction (H1) and having a width wider than that of the pair of first side walls (91), wherein the end portions of the pair of second side walls (92) on the opening (94) side have an abnormality in which they bulge outward. A method for manufacturing a container (90C) including a preparation step in which a press-molded product (90) is prepared, and a correction processing step in which abnormal bulges in the pair of second side walls (92) of the press-molded product (90) are removed to process the press-molded product (90) into a rectangular parallelepiped container (90C), wherein in the correction processing step, at least both lateral ends of the end of the second side wall (92) of the press-molded product (90) on the opening (94) side are pressed from the outside.

[0063] [Feature 18] Feature 17: The manufacturing method for the container (90C) according to Feature 17, wherein in the correction processing step, the entire lateral end of the second side wall (92) on the opening (94) side is pressed from outside.

[0064] Abnormal bulging, which can occur in a press-formed product of a container structure with one open side, occurs in the form of an arc-shaped outward bulge in the opening-side end of a pair of second side walls, which are wider than a pair of first side walls, across the entire lateral direction. In other words, compared to a flat, normal second side wall without a bulge, the abnormal second side wall has its lateral ends tilted outward and curved so that the radius of curvature decreases toward the lateral center. In contrast, the technologies of Features 1 and 17 press at least both lateral ends of the opening-side end of the second side wall from the outside. This eliminates the outward tilt of the lateral ends of the abnormal second side wall, which was impossible with conventional technologies, and more reliably eliminates abnormal bulging of the second side wall than with conventional technologies.

[0065] Although pressing only the lateral end of the second side wall can suppress abnormal bulging of the second side wall compared to conventional methods, pressing the middle portion between both lateral ends of the second side wall applies a pressing force in a direction separating both lateral ends of the second side wall from each other, thereby facilitating removal of the bulge. Furthermore, as in Features 2 and 18, pressing the entire lateral end of the opening side of the second side wall from the outside promotes removal of the bulge throughout the entire side, thereby increasing the flatness of the second side wall.

[0066] Furthermore, in order to press the entire second side wall in the lateral direction, as in Features 3 and 14, it is preferable that the intersection line between a pair of pressing surfaces of a pair of pressing members pressing the second side wall and an imaginary planar cross section parallel to the lateral direction (first direction) of the second side wall is a straight line, but the intersection line may also be curved so as to bulge or recess.

[0067] Furthermore, in a third direction orthogonal to the first and second directions, the pair of pressing surfaces of the pair of pressing members may be entirely flat. However, it is preferable that the pressing surfaces curve away from the second side wall as they move away from the open end of the second side wall, or that each pressing surface include a first pressing plane orthogonal to the second direction and a second pressing plane inclined relative to the second direction, as in Features 4 and 14. These shapes can prevent the occurrence of pressure marks at the boundary between the pressed and non-pressed portions of the second side wall. When each pressing surface includes a first pressing plane orthogonal to the second direction and a second pressing plane inclined relative to the second direction, it is preferable that the inclination angle of the second pressing plane relative to the plane extending from the first pressing plane be 2 to 4°, and that the corners between the first pressing plane and the second pressing plane be rounded, as in Feature 5, in order to effectively prevent pressure marks.

[0068] Furthermore, when the opening side end of the second side wall of the press-formed product is pressed as described above, the work support member that supports the press-formed product may be structured to fit, for example, onto the outside of the bottom wall side end of the press-formed product. However, as in Feature 6, it is preferable that the work support member be structured so that it can fit onto the inside of the press-formed product and have positioning fitting portions that overlap the bottom wall, a pair of first side walls, and a pair of second side walls so as to position the press-formed product in three dimensions. Furthermore, as in Features 6 and 7, by providing the work support member with two pairs of end support portions that extend in the third direction and overlap from the inside at both lateral end positions of the pair of second side walls of the press-formed product, and a pair of side recesses that are recessed between each pair of end support portions and face the pair of second side walls, when the pair of second side walls are pressed by the pressing member, both lateral end portions of the second side walls are clamped between the pressing member and the end support portions, effectively eliminating the outward tilt of the lateral end portions of the second side walls and effectively eliminating the bulge of the second side walls.

[0069] In Feature 8, the side recess has a pair of slopes that gradually deepen with increasing distance from the adjacent end support portions, thereby preventing abrupt deformation of the second side wall and suppressing the occurrence of pressure marks. To effectively suppress the occurrence of pressure marks, as in Feature 9, the slope angle of the pair of slopes with respect to the first direction is preferably 10 to 15°.

[0070] Furthermore, the end support portion may have an outer surface flush with the positioning fitting portion, but in Feature 10, the end support portion is recessed from the positioning fitting portion, making both lateral ends of the second side wall more susceptible to pressure and deformation, and more effectively eliminating bulges in the second side wall. In this case, as in Feature 11, the amount of recession of the end support portion from the positioning fitting portion is preferably 1 to 2 mm. Furthermore, in Feature 12, the step surface between the end support portion and the positioning fitting portion is an arc surface that continues to the positioning fitting portion, thereby preventing pressure marks from occurring.

[0071] In many cases, the abnormal bulge of the second side wall narrows in width as it moves away from the opening of the press-molded product. In view of this, as in Feature 13, it is preferable that the side recess be larger in the third direction than the end support portion and be formed to face the range from the end of the opening side of the press-molded product to a position close to the bottom wall.

[0072] Furthermore, as in Feature 16, by configuring the device to include a measuring device that measures the amount of bulge of the pair of second side walls and a control device that controls the amount of pressure applied to the pair of second side walls by the pair of pressing members based on the measurement results from the measuring device, it is possible to address variations in the amount of bulge.

[0073] Although the present specification and drawings disclose specific examples of the technology included in the scope of the claims, the technology described in the claims is not limited to these specific examples, but also includes various modifications and variations of the specific examples, and also includes parts of the specific examples taken out alone. [Explanation of symbols]

[0074] 10A correction processing device 11 Work support member 12 Side recess 12A Slope 13 End support 13R arc surface 15 Positioning fitting part 30 Pressing member 31 Pressing surface 31A First pressing plane 31B Second pressing plane 79 Measuring Equipment 83 Slide drive mechanism 88A Control Unit 90 Press-molded products 90C container 91 First side wall 92 Second side wall 93 Bottom Wall 94 Aperture H1 1st direction H2 2nd direction H3 3rd direction L1 cross line P1 1st intermediate position P2 2nd intermediate position

Claims

1. A corrective machining device for correctively machining a press-formed product having a container structure with one open surface, the press-formed product including a bottom wall, an opening facing the bottom wall, a pair of first side walls facing each other in a first direction, and a pair of second side walls facing each other in a second direction perpendicular to the first direction and having a width wider than that of the pair of first side walls, the corrective machining device removing abnormal outward bulges at the opening-side ends of the pair of second side walls, a workpiece support member that fits inside the press-formed product and supports the press-formed product; a pair of pressing members configured to press from outside at least both lateral end portions of an end portion of the second side wall on the opening side of the press-formed product supported by the work support member, A correction processing device that does not press the pair of first side walls.

2. 2. The correction machining device according to claim 1, wherein the pair of pressing members press the entire lateral portion of the end of the second side wall on the opening side from outside.

3. 3. The correction machining device according to claim 2, wherein an intersection line between a pair of pressing surfaces of the pair of pressing members that press the pair of second side walls and an imaginary planar cross section parallel to the first direction is a straight line.

4. When a direction perpendicular to the first direction and the second direction is defined as a third direction, The pair of pressing surfaces of the pair of pressing members that press the pair of second side walls include: a first pressing plane that faces a range from an end of the pair of second side walls on the opening side to a first intermediate position in the third direction and is perpendicular to the second direction; a second pressing plane that faces a range of the pair of second side walls from the first intermediate position to a second intermediate position that is farther from the opening, and that inclines so as to move away from the pair of second side walls as it moves away from the first pressing plane; The correction processing device according to claim 1 , further comprising:

5. The correction processing device according to claim 4, wherein the inclination angle of the second pressing plane relative to the plane extending from the first pressing plane is 2 to 4 degrees, and the corners between the first pressing plane and the second pressing plane are R-chamfered.

6. The workpiece support member is formed so as to be able to fit inside the press-formed product, When a direction perpendicular to the first direction and the second direction is defined as a third direction, The workpiece support member has: two pairs of end support portions extending in the third direction and overlapping from inside both end positions of the pair of second side walls of the press-formed product in the lateral direction; a pair of side recesses formed by recessing between each pair of the end support portions and facing the pair of second side walls; a positioning and fitting portion that overlaps the bottom wall, the pair of first side walls, and the pair of second side walls so as to three-dimensionally position the press-formed product; 2. The correction processing device according to claim 1, further comprising:

7. The correction processing device according to claim 6, wherein the pair of pressing members are formed to press at least the portions of both lateral ends of the pair of second side walls that overlap with the end support portions from the inside and the portions that overlap with the side recesses.

8. 7. The correction machining device according to claim 6, wherein each of the side recesses has a pair of slopes that gradually become deeper with increasing distance from the end support portions on both sides thereof.

9. 9. The correction machining device according to claim 8, wherein the pair of inclined surfaces have an inclination angle of 10 to 15 degrees with respect to the first direction.

10. 7. The correction machining device according to claim 6, wherein the end support portion is recessed from the positioning and fitting portion.

11. 11. The correction machining device according to claim 10, wherein the end support portion is recessed from the positioning fitting portion by an amount of 1 to 2 mm.

12. 11. The correction machining device according to claim 10, wherein a step surface between the end support portion and the positioning and fitting portion is an arcuate surface that continues to the positioning and fitting portion.

13. The correction machining device according to claim 6 , wherein the side recess is larger than the end support portion in the third direction and is formed to face a range from the end of the press-formed product on the opening side to a position near the bottom wall.

14. a pair of pressing surfaces of the pair of pressing members that press the pair of second side walls have a width equal to or greater than the width of the work support member, and an intersection line between an imaginary planar cross section parallel to the first direction and the pair of pressing surfaces is a straight line; When a direction perpendicular to the first direction and the second direction is defined as a third direction, The pair of pressing surfaces include: a first pressing plane that faces a range from an end of the pair of second side walls on the opening side to a first intermediate position in the third direction and is perpendicular to the second direction; A correction processing device as described in any one of claims 6 to 13, including a second pressing plane that faces the pair of second side walls in a range from the first intermediate position to a second intermediate position further away from the opening, and that slopes away from the pair of second side walls as it moves away from the first pressing plane.

15. The end support portion is recessed from the positioning fitting portion, The correction machining device according to claim 14, wherein a step portion between the end support portion and the positioning fitting portion is disposed between the first intermediate position and the second intermediate position.

16. a measuring device for measuring the amount of expansion of the pair of second side walls; 14. The correction processing device according to claim 1, further comprising: a control device that controls the amount of pressure applied by the pair of pressure members to the pair of second side walls based on the measurement result of the measurement device.

17. a preparation step in which a press-molded product is prepared, the press-molded product having a container structure with one side open, the press-molded product including a bottom wall, an opening facing the bottom wall, a pair of first side walls facing each other in a first direction, and a pair of second side walls facing each other in a second direction perpendicular to the first direction and having a width wider than that of the pair of first side walls, the pair of second side walls having an abnormality in which the end portions of the pair of second side walls on the opening side are bulged outward; a correction processing step of removing abnormal bulges of the pair of second side walls of the press-molded product to process the product into a rectangular parallelepiped container, In the correction processing step, the press-formed product is supported by a work support member that fits inside the press-formed product, and the first side wall of the press-formed product is not pressed, and at least both lateral ends of the opening side end of the second side wall are pressed from the outside.

18. The method for manufacturing a container according to claim 17, wherein the correction processing step includes pressing the entire lateral end of the second side wall on the opening side from outside.

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