Screw manufacturing system

Abstract

To provide a screw production system which suppresses deterioration in safety of an operator and can improve the efficiency of screw production.SOLUTION: A screw production system includes a form-rolling device which produces a screw by rolling, a cutting device which produces the screw by cutting, and a control device which receives specification information of the produced screw and controls the form-rolling device and the cutting device based on the received specification information. The control device preferably includes a generation part which generates machining conditions based on the specification information and a transmission part which transmits the generated machining conditions to the form-rolling device or the cutting device. Therein, the machining conditions contain information which exhibits form-rolling machining or cutting machining, and the transmission part, when the machining conditions are required from the form-rolling device, transmits the machining conditions linked with information which exhibits the form-rolling machining to the form-rolling device, and when the machining conditions are required from the cutting device, transmits to the form-rolling device the machining conditions linked with information which exhibits the cutting machining.SELECTED DRAWING: Figure 1

Description

Technical Field

[0006] , , ,

[0001] The present technology relates to a screw manufacturing system for manufacturing screws, particularly long screws.

Background Art

[0002] Conventionally, a screw manufacturing apparatus by forging and a screw manufacturing apparatus by screw cutting (machining) have been proposed (see, for example, Patent Document 1). An operator checks the order form to confirm whether it is manufacturing by forging or manufacturing by cutting, and transports the workpiece to a screw manufacturing apparatus by forging or a screw manufacturing apparatus by cutting. The operator grips the workpiece and brings it into contact with a forging die or a cutting edge to form a screw on the workpiece.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, when an operator grips a workpiece to manufacture a screw, there is a risk of reducing the safety of the operator. Also, it is difficult to improve the efficiency of screw manufacturing. There is also a risk of causing human errors or reducing quality stabilization.

[0005] The present disclosure has been made in view of such circumstances, and an object thereof is to provide a screw manufacturing system that can suppress a decrease in the safety of an operator, improve the efficiency of screw manufacturing, and suppress the occurrence of human errors and a decrease in quality stabilization.

Means for Solving the Problems

[0006] A screw manufacturing system according to one embodiment of the present disclosure comprises a rolling machine for manufacturing screws by rolling, a cutting machine for manufacturing screws by cutting, and a control device that receives specification information of the screws to be manufactured and controls the rolling machine and the cutting machine based on the received specification information. [Effects of the Invention]

[0007] In a screw manufacturing system according to one embodiment of this disclosure, the rolling machine and cutting machine are controlled based on the specification information of the screw to be manufactured, so that the operator does not need to grip the workpiece, thus suppressing a decrease in safety. Furthermore, since the rolling machine and cutting machine automatically manufacture screws based on the specification information, the efficiency of screw manufacturing can be improved, and the occurrence of human error and a decrease in quality stability can be suppressed. [Brief explanation of the drawing]

[0008] [Figure 1] This is a block diagram of a screw manufacturing system. [Figure 2] This is a front perspective view of the thread rolling machine. [Figure 3] This is a rear perspective view of the thread rolling machine. [Figure 4] This is a plan view of the thread rolling machine. [Figure 5] This is a perspective view of the extraction machine. [Figure 6] This is a right-side diagram illustrating the operation of the extraction machine. [Figure 7] This is a schematic perspective view of the conveying machine. [Figure 8] This is a schematic perspective view of the extraction machine, conveying machine, and length measuring machine. [Figure 9] This is a simplified perspective view of the measuring instrument as seen from the front. [Figure 10] This is a simplified perspective view of the measuring instrument as seen from the rear. [Figure 11] This is a schematic perspective view of a length measuring machine and a rolling positioning machine. [Figure 12] This is a schematic perspective view of a thread rolling positioning machine. [Figure 13]It is a schematic perspective view of a length measuring machine, a forging position determining machine, and a carry-out conveyor. [Figure 14] It is a schematic perspective view of the carry-out conveyor viewed from the rear side. [Figure 15] It is a flowchart for explaining the screw manufacturing process by the forging control device. [Figure 16] It is a schematic perspective view of the cutting apparatus. [Figure 17] It is a schematic plan view of the cutting apparatus. [Figure 18] It is an explanatory diagram for explaining the removal of chips by the removal mechanism. [Figure 19] It is an explanatory diagram for explaining the removal of chips by the removal mechanism. [Figure 20] It is an explanatory diagram for explaining the removal of chips by the removal mechanism. [Figure 21] It is an explanatory diagram for explaining the removal of chips by the removal mechanism. [Figure 22] It is an explanatory diagram for explaining the removal of chips by the removal mechanism. [Figure 23] It is an explanatory diagram for explaining the removal of chips by the removal mechanism.

Mode for Carrying out the Invention

[0009] Hereinafter, the present invention will be described based on the drawings showing the screw manufacturing system 1 according to the embodiment. FIG. 1 is a block diagram of the screw manufacturing system 1.

[0010] The screw manufacturing system 1 includes a terminal device 2, a server 3, a forging device 4, and a cutting device 7. The terminal device 2 is, for example, a personal computer. The terminal device 2 includes a control unit 2a, a storage unit 2b, a reception unit 2d, and a communication unit 2c. The control unit 2a is, for example, a CPU or MPU. The storage unit 2b is configured to be rewritable and is, for example, a nonvolatile memory or a hard disk. The reception unit 2d is, for example, a keyboard, a mouse, a touch panel, etc., and receives the operation of the user. The terminal device 2 communicates with the server 3 via the communication unit 2c.

[0011] The thread rolling machine 4 comprises a thread rolling control device 5 and an operation panel 6. The thread rolling control device 5 comprises a control unit 5a, a storage unit 5b, and a communication unit 5c. The control unit 5a is, for example, a CPU or MPU. The storage unit 5b is configured to be rewritable and is, for example, a non-volatile memory or a hard disk. The thread rolling control device 5 communicates with the server 3 via the communication unit 5c. The control unit 5a executes screw manufacturing processes, etc., based on the program stored in the storage unit 5b. The operation panel 6 accepts operations from the operator. The operation panel 6 has, for example, a keyboard, switches, etc. The switches include position switches and start switches. The operation panel 6 has a display unit 6a. The display unit 6a is, for example, a display and displays information. The display unit 6a may be configured as a touch panel and may also be used in conjunction with the operation panel 6.

[0012] The cutting device 7 comprises a cutting control device 8 and an operation panel 9. The cutting control device 8 comprises a control unit 8a, a storage unit 8b, and a communication unit 8c. The control unit 8a is, for example, a CPU or MPU. The storage unit 8b is configured to be rewritable and is, for example, a non-volatile memory or a hard disk. The control unit 8a executes screw manufacturing processes, etc., based on a program stored in the storage unit 8b. The cutting control device 8 communicates with the server 3 via the communication unit 8c. The operation panel 9 accepts operations from the operator. The operation panel 9 has, for example, a keyboard, switches, etc. The switches include position switches and start switches. The operation panel 9 includes a display unit 9a. The display unit 9a is, for example, a display and displays information. The display unit 9a may be configured as a touch panel and may be used in conjunction with the operation panel 9.

[0013] Server 3 comprises a control unit 3a, a storage unit 3b, and a communication unit 3c. The control unit 3a is, for example, a CPU or MPU. The storage unit 3b is configured to be rewritable and is, for example, a non-volatile memory or a hard disk. Server 3 communicates with terminal device 2, rolling control device 5, and cutting control device 8 via the communication unit 3c.

[0014] For each order, the order information is stored as order data in server 3. This order data also includes screw specification information. The user operates the reception unit 2d to select the same screw processing group from the order data and sends it to server 3. Server 3 stores the screw specification information for each processing group in the storage unit 3b.

[0015] The operator operates the control panel 6 of the thread rolling machine 4 and inputs a request to send an unprocessed processing group. The thread rolling control device 5 requests the server 3 to send the unprocessed processing group. The server 3 sends the unprocessed processing group to the thread rolling control device 5. The thread rolling control device 5 displays the unprocessed processing group on the display unit 6a. The operator operates the control panel 6 and selects the unprocessed processing group displayed on the display unit 6a. The thread rolling control device 5 processes the selected unprocessed processing group. That is, the thread rolling control device 5 generates processing conditions based on the screw specification information of the processing group and processes the workpiece 100 into a screw based on the generated processing conditions. When the processing of the processing group is complete, the thread rolling control device 5 sends a processing completion notification to the server 3. Upon receiving the processing completion notification, the server 3 stores a processing completion flag associated with the processing group. Processing groups associated with the processing completion flag are processed processing groups, and processing groups not associated with the processing completion flag are unprocessed processing groups.

[0016] The operator operates the control panel 9 of the cutting device 7 and inputs a request to send an unprocessed machining group. The cutting control device 8 requests the server 3 to send the unprocessed machining group. The server 3 sends the unprocessed machining group to the cutting control device 8. The cutting control device 8 displays the unprocessed machining group on the display unit 9a. The operator operates the control panel 9 and selects the unprocessed machining group displayed on the display unit 9a. The cutting control device 8 executes the selected unprocessed machining group. That is, the cutting control device 8 generates machining conditions based on the screw specification information of the machining group and machines the workpiece 100 into a screw based on the generated machining conditions. When the processing of the machining group is completed, the cutting control device 8 sends a processing completion notification to the server 3. Upon receiving the processing completion notification, the server 3 stores a processing completion flag associated with the machining group. A machining group associated with the processing completion flag is a processed machining group, and a machining group not associated with the processing completion flag is an unprocessed machining group. The user can access the server 3 via the terminal device 2 to check whether a machining group is processed or unprocessed. For processing groups requiring pre-processing, the thread rolling control device 5 and the cutting control device 8 also display whether the pre-processing has been completed. Alternatively, the server 3 may generate processing conditions based on the screw specifications of the processing group and transmit these processing conditions to the thread rolling control device 5 and the cutting control device 8.

[0017] The following describes the specifications. The specifications include information indicating whether the process is rolled or cut, information about the workpiece 100, the length of the thread, and the thread standard. The information about the workpiece 100 includes the material, diameter, and length. The thread standard includes the thread pitch, outer diameter, and root diameter.

[0018] The processing conditions will now be described. The processing conditions include information indicating whether rolling or cutting is being performed, the height of the rolling positioning machine 50 and cutting positioning machine 94 (described later), the rolling pressure of the rolling machine 80 (described later), the chucking pressure of the cutting machine 96 (described later), the rolling time of the rolling machine 80, the rotational speed of the cutting blade 231 of the cutting machine 96, the feed rate of the workpiece 100, and the distance traveled by the workpiece 100.

[0019] Figure 2 is a front side perspective view of the rolling machine 4, Figure 3 is a rear side perspective view of the rolling machine 4, and Figure 4 is a plan view of the rolling machine 4. The following description will use the up, down, front, back, left, and right directions shown in the figures. The up, down, front, back, left, and right directions shown in the figures are examples only, and the directions are not limited to these. The rolling machine 4 comprises a take-out machine 10, a conveyor machine 20, a length measuring machine 40, a rolling positioning machine 50, a rolling machine 80, a discharge conveyor 60, and a receiving box 70. The conveyor machine 20 is positioned behind the take-out machine 10. The length measuring machine 40 is positioned behind the conveyor machine 20. The rolling positioning machine 50 is positioned behind the length measuring machine 40. The rolling machine 80 is positioned to the left of the rolling positioning machine 50. The discharge conveyor 60 is positioned to the right of the rolling machine 80 and behind the rolling positioning machine 50. The discharge conveyor 60 extends to the left and right. The receiving box 70 is positioned in front of the discharge conveyor 60 and to the right of the extraction machine 10.

[0020] Figure 5 is a perspective view of the extraction machine 10, and Figure 6 is a right side explanatory view illustrating the operation of the extraction machine 10. The extraction machine 10 includes an input box 11 into which the workpiece 100 is fed. The input box 11 includes a bottom portion 11a that slopes downward toward the rear, a front portion 11b that protrudes approximately perpendicularly from the front edge of the bottom portion 11a, and side portions 11c that protrude approximately perpendicularly from the left and right edges of the bottom portion 11a. The top and rear of the input box 11 are open. A first fixing plate 12a is provided on the rear side of the input box 11, approximately perpendicular to the bottom portion 11a. The first fixing plate 12a extends upward. A gap, i.e., a first gap 14a, is provided between the first fixing plate 12a and the bottom portion 11a.

[0021] A second fixing plate 12b is provided above the first fixing plate 12a, approximately parallel to the first fixing plate 12a. The lower end of the second fixing plate 12b is approximately the same as the upper end of the first fixing plate 12a. The second fixing plate 12b is positioned behind the first fixing plate 12a, and a gap, i.e., a second gap 14b, is provided between the second fixing plate 12b and the first fixing plate 12a. A third fixing plate 12c is provided above the second fixing plate 12b, approximately parallel to the second fixing plate 12b. The lower end of the third fixing plate 12c is approximately the same as the upper end of the second fixing plate 12b. The third fixing plate 12c is positioned behind the second fixing plate 12b, and a gap, i.e., a third gap 14c, is provided between the third fixing plate 12c and the second fixing plate 12b. A stopper 12d protrudes upward from the upper rear edge of the third fixing plate 12c. The stopper 12d is configured to be rotatable.

[0022] A first movable plate 13a is provided in the first gap 14a, a second movable plate 13b is provided in the second gap 14b, and a third movable plate 13c is provided in the third gap 14c. The first to third movable plates 13c are substantially parallel to the first to third fixed plates 12c and can move up and down along the first to third fixed plates 12c. A lifting cylinder 15 is provided on the underside of the bottom surface 11a. The rod of the lifting cylinder 15 is connected to the first to third movable plates 13c via a connecting member 16 (not shown). The rod of the lifting cylinder 15 moves up and down, and the first to third movable plates 13c move up and down simultaneously. As shown in Figures 5 and 6A, in the initial state, the vertical position of the upper end of the first movable plate 13a is approximately the same as the lower end of the first fixed plate 12a, the vertical position of the upper end of the second movable plate 13b is approximately the same as the lower end of the second fixed plate 12b, and the vertical position of the upper end of the third movable plate 13c is approximately the same as the lower end of the third fixed plate 12c.

[0023] As shown in Figure 6A, the operator places the workpiece 100 into the input box 11. One of the workpieces 100 rolls to the first fixed plate 12a due to the inclination of the bottom surface 11a and stops on the upper surface of the first movable plate 13a. As shown in Figure 6B, the rod of the lifting cylinder 15 rises, causing the first to third movable plates 13a to 13c to rise, and the workpiece 100 placed on the upper surface of the first movable plate 13a also rises. As shown in Figure 6C, when the vertical position of the upper end of the first movable plate 13a and the vertical position of the upper end of the first fixed plate 12a become approximately the same, the workpiece 100 placed on the upper surface of the first movable plate 13a rolls to the second movable plate 13b due to the inclination of the upper surface of the first movable plate 13a and stops on the upper surface of the first fixed plate 12a. Next, as shown in Figure 6A, the rod of the lifting cylinder 15 descends, causing the first to third movable plates 13a to 13c to descend. The workpiece 100, positioned on the upper surface of the first fixed plate 12a, rolls to the second fixed plate 12b due to the inclination of the upper surface of the second movable plate 13b, and stops on the upper surface of the second movable plate 13b. In this way, the lifting and lowering of the first to third movable plates 13c is repeated, and the workpieces 100 are carried one by one to the upper surface of the third fixed plate 12c and supported by the stopper 12d. As shown by the dashed line in Figure 6C, the stopper 12d rotates, and a single workpiece 100 moves toward the measuring position P1 (see Figure 7). That is, the extraction machine 10 can extract the workpieces 100 one by one. As shown in Figure 5, the extraction machine 10 is connected to the conveyor 20 via a connecting member 16.

[0024] Figure 7 is a schematic perspective view of the conveyor 20. The conveyor 20 comprises a vertical movement section 20a, a front-to-back movement section 20b, a left-to-right movement section 20c, a first gripping section 34, and a second gripping section 35. The vertical movement section 20a comprises two vertical rails 21, two vertical sliders 22, a vertical movement frame 23, and a vertical cylinder 24. The two vertical rails 21 extend vertically, are spaced a predetermined distance apart horizontally, and are fixed to the rear surface of a connecting member 16. The vertical cylinder 24 is fixed to the connecting member 16 between the two vertical rails 21. The vertical cylinder 24 has a vertical rod 24a that protrudes downward and moves up and down. The vertical movement frame 23 is slidably connected to each vertical rail 21 via each vertical slider 22. The vertical rod 24a is connected to the vertical movement frame 23, and the vertical movement frame 23 moves up and down by the movement of the vertical rod 24a.

[0025] The front-rear moving section 20b comprises two front-rear rails 25, a rail support section 26, front-rear cylinders 27, a first support plate 29a, a second support plate 29b, and a connecting shaft 28. The rail support section 26 is fixed to the rear side of the vertical moving frame 23. The rail support section 26 comprises a rod extending to the left and right, and sliders fixed to the underside of each of the left and right ends of the rod. The left and right sliders are slidably connected to the two front-rear rails 25. The two front-rear rails 25 are positioned below the vertical moving frame 23. The two front-rear rails 25 extend front-rear and are separated by a predetermined distance to the left and right. The front-rear rails 25 are movable back and forth. The front-rear cylinders 27 are fixed to the underside of the vertical moving frame 23 between the two front-rear rails 25. The front-rear cylinders 27 have a front-rear rod 27a that protrudes rearward and moves back and forth. The first support plate 29a is fixed opposite the rear surface of the rail support section 26. The rear ends of the front and rear rods 27a are connected to the first support plate 29a. A second support plate 29b is positioned opposite the rear of the first support plate 29a. The first support plate 29a and the second support plate 29b are connected by a connecting shaft 28 that extends in the front and rear directions. The first support plate 29a is fixed to the first left and right cylinders 30, which will be described later. The second support plate 29b is fixed to the second left and right cylinders 31, which will be described later. The lower sides of the two front and rear rails 25 are fixed to the first left and right cylinders 30 and the second left and right cylinders 31. The front and rear rods 27a move back and forth, causing the first support plate 29a, the second support plate 29b, the first left and right cylinders 30, the second left and right cylinders 31, and the front and rear rails 25 to move back and forth.

[0026] The left-right moving section 20c comprises a first left-right cylinder 30, a second left-right cylinder 31, a first left-right rail 32, a second left-right rail 33, a first left-right slider, a second left-right slider, a first gripping section 34, and a second gripping section 35. The first left-right cylinder 30 is supported by a first support plate 29a below the front-rear rail 25. A first left-right slider 32a is fixed to the lower surface of the first left-right cylinder 30. The first left-right rail 32 is slidably connected to the first left-right slider 32a. The first left-right rail 32 extends to the left and right. The first left-right cylinder 30 has a first left-right rod 30a that protrudes to the right and moves left and right. The tip of the first left-right rod 30a is connected to the first left-right rail 32 via a connecting section. The left-right movement of the first left-right rod 30a causes the first left-right rail 32 to move left and right.

[0027] The second left and right cylinders 31 are supported by the second support plate 29b below the front and rear rails 25. The second left and right sliders 33a are fixed to the lower surface of the second left and right cylinders 31. The second left and right rails 33 are slidably connected to the second left and right sliders 33a. The second left and right rails 33 extend to the left and right. The second left and right cylinders 31 have a second left and right rod 31a that protrudes to the right and moves left and right. The tip of the second left and right rod 31a is connected to the second left and right rails 33 via a connecting part. The left and right movement of the second left and right rod 31a causes the second left and right rails 33 to move left and right.

[0028] The first gripping section 34 is connected to the first left and right rails 32. The first gripping section 34 has a plurality of fingers 34a. The second gripping section 35 is connected to the second left and right rails 33. The second gripping section 35 has a plurality of fingers 35a. The plurality of fingers 35a are arranged in the left-right direction and can be opened and closed in the front-back direction. Each finger 34a, 35a is provided with finger cylinders 34b, 35b, and the fingers 34a, 35a are opened and closed by the driving of the finger cylinders 34b, 35b. The first gripping section 34 and the second gripping section 35 move up and down by the vertical movement section 20a, move back and forth by the front-back movement section 20b, and move left and right by the left-right movement section 20c.

[0029] The conveyor 20 grips the workpiece 100 or screw with the first gripping section 34 or the second gripping section 35 and moves it up and down, forward and backward, or left and right to convey it to the length measurement position P1, the rolling position P2, or the discharge position. The rolling position P2 is located behind the length measurement position P1, and the discharge position is located behind the rolling position P2. The front-to-back distance between the length measurement position P1 and the rolling position P2 is approximately equal to the front-to-back distance between the first gripping section 34 and the second gripping section 35. The front-to-back distance between the rolling position P2 and the discharge position is approximately equal to the front-to-back distance between the first gripping section 34 and the second gripping section 35.

[0030] Figure 8 is a schematic perspective view of the extraction machine 10, the conveyor 20, and the length measuring machine 40. Figure 9 is a schematic perspective view of the length measuring machine 40 as seen from the front. Figure 10 is a schematic perspective view of the length measuring machine 40 as seen from the rear. The length measuring machine 40 is located behind the extraction machine 10 and below the conveyor 20. The length measuring machine 40 comprises a frame 41, a plurality of receiving parts 42, a reference plate 43, a pressing plate 45, a positioning motor 44, and a pressing motor 46. Each receiving part 42 is groove-shaped and extends to the left and right. The plurality of receiving parts 42 are arranged in the left-right direction and fixed to the frame 41. The length measuring position P1 is the front-rear position of the receiving part 42. The reference plate 43 is provided to the left of the leftmost receiving part 42. The reference plate 43 is configured to be movable in the left-right direction and is moved in the left-right direction by the positioning motor 44.

[0031] At the rear of the multiple receiving portions 42, rails 49 extending left and right are fixed to the frame 41. A pressing plate 45 is slidably connected to the rails 49. The pressing plate 45 has an L-shape when viewed from the right, and comprises a first portion extending front and rear, and a second portion extending downward from the front end of the first portion. The first portion is located above the receiving portions 42, and the second portion is positioned inside the receiving portions 42. The pressing plate 45 and the reference plate 43 are positioned facing each other in the left-right direction. A chain 48 and two sprockets 47 are positioned below the rails 49. The two sprockets 47 are positioned at the left and right ends of the length measuring device, respectively, with the front-rear direction as the axis of rotation. The chain 48 is hung on the two sprockets 47. The pressing plate 45 is connected to the chain 48. The right sprocket 47 is rotated by a pressing motor 46. An encoder 46a is attached to the pressing motor 46. The pressing motor 46 drives the pressing plate 45 from side to side. The encoder 46a detects the amount of movement of the pressing plate 45. The position of the reference plate 43 determines the length of the threads (length of the thread grooves) formed on the workpiece 100. As the reference plate 43 is positioned further to the left, the length of the threads on the workpiece 100 becomes longer.

[0032] When the workpiece 100 is placed in the receiving section 42, the presence of the workpiece 100 is detected by a sensor (not shown), and the workpiece 100 is pressed against the reference plate 43 by the pressing plate 45. The workpiece 100 is positioned by being pressed against the reference plate 43. Based on the amount of movement detected by the encoder 46a, the rolling control device 5 determines whether the length of the workpiece 100 matches the length of the workpiece 100 included in the order data (processing group) received from the server 3. If they do not match, error processing is performed, such as displaying an error message or stopping the rolling device 4.

[0033] Figure 11 is a schematic perspective view of the length measuring machine 40 and the rolling positioning machine 50, and Figure 12 is a schematic perspective view of the rolling positioning machine 50. The rolling positioning machine 50 is positioned behind the length measuring machine 40. The rolling positioning machine 50 comprises an upward-extending frame 51, two rails 52, a slider 53, a lifting ball screw mechanism 54, a base 55, and a plurality of support members 56. Two rails 52 are attached to the rear surface of the frame 51. The two rails 52 extend vertically and are separated by a predetermined distance in the left-right direction. The slider 53 is slidably connected to the two rails 52. The nuts of the lifting ball screw mechanism 54 are connected to the slider 53. The motor and screw shaft of the lifting ball screw mechanism 54 have their rotation axis in the vertical direction. The rotation of the motor and screw shaft causes the nuts and slider 53 to move up and down.

[0034] A base 55 extending left and right is provided at the upper end of the slider 53. Multiple support members 56 are arranged horizontally on the upper surface of the base 55. Two rollers 57 are rotatably provided at the upper end of each support member 56. The two rollers 57 are arranged front to back. The axis of rotation of the rollers 57 is in the left to right direction. The central position between the two rollers 57 in the front to back direction is the rolling position P2. A proximity sensor 58 is provided at the left end of the base 55. The workpiece 100 whose length has been measured by the length measuring machine 40 is transported by the first gripping unit 34 from the length measuring position P1 to the space between the two rollers 57 provided at the upper end of each support member 56, i.e., the rolling position P2.

[0035] At the rolling position P2, the left end of the workpiece 100 is positioned between the multiple rolling dies in the rolling machine 80 (see Figure 4). When the workpiece 100 is detected by the proximity sensor 58, the multiple rolling dies approach the workpiece 100, rolling is performed on the workpiece 100, and a male thread is formed on the left end of the workpiece 100. In other words, a screw is manufactured. The screw manufactured by the rolling machine 80 is gripped by the second gripping unit 35 and transported to the discharge conveyor 60. When the second gripping unit 35 grips the screw, the first gripping unit 34 simultaneously grips the workpiece 100 at the length measurement position P1. When the second gripping unit 35 transports the screw to the discharge position P3, the first gripping unit 34 simultaneously transports the workpiece 100 to the rolling position P2.

[0036] Figure 13 is a schematic perspective view of the length measuring machine 40, the rolling positioning machine 50, and the discharge conveyor 60, and Figure 14 is a schematic perspective view of the discharge conveyor 60 as seen from the rear. The discharge conveyor 60 comprises a frame 61, an endless belt 63, two pulleys 62, a transport motor 64, a kicker 65, and a kicker cylinder 68. The two pulleys 62 have their rotation axis in the front-rear direction and are provided at both the left and right ends of the upper surface of the frame 61. The belt 63 is stretched between the two pulleys 62. The right pulley 62 is rotated by the transport motor 64, and the upper surface of the belt 63 moves from left to right. The left-right dimension between the two pulleys 62 is longer than the left-right dimension of the length measuring machine 40 and the rolling positioning machine 50, respectively. In the left-right direction, the positions of the measuring machine 40, the rolling positioning machine 50, and the left end of the discharge conveyor 60 are approximately the same, and the right portion of the discharge conveyor 60 protrudes to the right of the measuring machine 40 and the rolling positioning machine 50.

[0037] A kicker 65 is provided on the right side of the discharge conveyor 60. The kicker 65 is positioned slightly above the upper surface of the belt 63. The kicker 65 has a plate portion 66 that extends in the left-right direction and is approximately perpendicular to the rotation axis of the pulley 62, and arch portions 67 provided at each end of the plate portion 66. The lower side of the arch portion 67 is open. A kicker cylinder 68 is provided on the rear side of the plate portion 66. The rod of the kicker cylinder 68 is connected to the rear surface of the plate portion 66. The plate portion 66 and the arch portion 67 move back and forth as the rod moves back and forth.

[0038] Multiple sliding plates 69 are provided on the right side of the discharge conveyor 60, in front of the belt 63. The multiple sliding plates 69 are arranged in the left-right direction to the right of the length measuring machine 40 and the rolling positioning machine 50. The sliding plates 69 are inclined to descend as they move towards the front. A receiving box 70 is positioned in front of the sliding plates 69 (see Figures 2 to 4).

[0039] The second gripping section 35 places the screw on the left side of the upper surface of the belt 63. The front-to-back position on the upper surface of the belt 63 is the aforementioned discharge position P3. The screw is transported to the right, passes inside the arch section 67, and is positioned in front of the kicker 65. Both ends of the screw are located inside the two arch sections 67, and the middle part of the screw is located in front of the plate section 66. The rod of the kicker cylinder 68 pushes the kicker 65 forward. Pushed by the kicker 65, the screw moves forward, slides on the sliding plate 69, and reaches the receiving box 70.

[0040] The aforementioned screw specifications include the diameter and material of the workpiece 100, the length of the screw, and the screw standard. The terminal device 2 generates the rolling height, which is the height of the rolling positioning machine 50 that aligns the position of the workpiece 100 with the position of the rolling machine 80, based on the diameter of the workpiece 100. The server 3 also generates the rolling pressure and rolling time of the rolling machine 80 based on the material of the workpiece 100, the length of the screw, and the screw standard (screw pitch, outer diameter, and root diameter). For example, the rolling pressure is calculated using the material of the workpiece 100, the length of the screw, and the screw standard as parameters.

[0041] Furthermore, the rolling time is calculated using the material of the workpiece 100, the length of the thread, and the thread specifications as parameters. Specifically, the number of rotations is calculated based on the material of the workpiece 100, the length of the thread, and the thread specifications. The number of rotations is the number of times the material is rotated by the rolling die to form a thread. For example, if the material of the workpiece 100 is SNR490B, the thread specifications are M20, and the length of the thread is 100 mm, the number of rotations is calculated to be 9.1. The rolling time is calculated as "number of rotations" ÷ ((spindle speed) / 60) * "number of die openings". The number of die openings is the number of times the workpiece 100 rotates for every one rotation of the rolling die. The spindle speed is the rotation speed of the rolling die. For example, if the die opening is 9.0 and the spindle speed is 26.5 rpm, the rolling time will be 9.1 / ((26.5 / 60)*9.0)=2.28 s. Alternatively, the rolling time calculated using the above formula can be manually corrected, and the corrected time can be used as the rolling time. Terminal device 2 transmits the rolling height, rolling pressure, and rolling time to server 3, and server 3 transmits them to the rolling control device 5. The rolling height, rolling pressure, and rolling time are included in the processing conditions.

[0042] Figure 15 is a flowchart illustrating the screw manufacturing process by the thread rolling control device 5. Initially, the operator has selected an unprocessed processing group, and the thread rolling control device 5 executes the screw manufacturing process on the selected processing group. The control unit 5a of the thread rolling control device 5 determines whether the position switch is turned on or not (S1). The operator places the workpiece 100 that matches the diameter, length, etc. displayed on the display unit 6a into the input box 11 and turns on the position switch on the operation panel 6. Before placing the workpiece 100, the thread rolling die may be changed according to the screw specifications displayed on the display unit 6a. If the position switch is not turned on (S1: NO), the control unit 5a returns to step S1.

[0043] If the position switch is turned on (S1:YES), the control unit 5a drives the rolling positioning machine 50 so that the vertical position of the roller 57 becomes the rolling height (S2). The control unit 5a determines whether the start switch is turned on or not (S3). If the start switch is not turned on (S3:NO), the control unit 5a returns to step S3. If the start switch is turned on (S3:YES), the take-out machine 10 is driven to transport the workpiece 100 to the length measuring machine 40, i.e., the length measuring position P1 (S4). The control unit 5a causes the length measuring machine 40 to perform positioning and measure the length of the workpiece 100 (S5).

[0044] The control unit 5a causes the conveyor 20 to transport the workpiece 100, whose length measurement is complete, to the roller 57 of the rolling positioning machine 50 (S6). The control unit 5a receives the detection signal from the proximity sensor 58 and determines whether or not the workpiece 100 has been detected (S7). If the workpiece 100 has not been detected (S7: NO), the control unit 5a returns to step S7. If the workpiece 100 has been detected (S7: YES), the control unit 5a causes the rolling machine 80 to roll the workpiece 100 to manufacture screws (S8). The control unit 5a causes the conveyor 20 to transport the screws to the discharge conveyor 60 and discharge the screws to the receiving box 70 on the discharge conveyor 60 (S9). The control unit 5a determines whether or not the manufacturing of the total number of screws to be manufactured has been completed (S10). If the manufacturing of the total number of screws has not been completed (S10: NO), the control unit 5a returns to step S4. If the manufacturing of all screws is completed (S10:YES), the control unit 5a terminates the screw manufacturing process in the thread rolling machine 4.

[0045] Figure 16 is a schematic perspective view of the cutting apparatus 7, and Figure 17 is a schematic plan view of the cutting apparatus 7. The cutting apparatus 7 comprises a crane 90, an extraction machine 91, a conveyor 92, a length measuring machine 93, a cutting positioning machine 94, a cutting machine 96, an output conveyor 95, and a receiving box 97. The extraction machine 91, conveyor 92, length measuring machine 93, cutting positioning machine 94, output conveyor 95, and receiving box 97 have a similar configuration to the extraction machine 10, conveyor 20, length measuring machine 40, rolling positioning machine 50, output conveyor 60, and receiving box 70 of the rolling apparatus 4, and a detailed explanation thereof is omitted.

[0046] The operator can use the crane 90 to load the workpiece 100 into the input box of the extraction machine 91 and to unload the screws from the receiving box 97. The cutting machine 96 is positioned to the left of the cutting positioning machine 94. The cutting machine 96 includes a chucking section (not shown) for chucking the workpiece 100, a cutting blade 231 for cutting the workpiece 100, a rotation mechanism 230 for rotating the cutting blade 231, a feeding mechanism (not shown) for feeding the workpiece 100 toward the cutting blade 231, a chip removal mechanism 200, and the like.

[0047] Terminal device 2 generates the cutting height, which is the height of the cutting positioning device 94 that aligns the position of the workpiece 100 with the position of the cutting machine 96, based on the diameter of the workpiece 100. Terminal device 2 also generates the chucking pressure of the cutting machine 96 based on the material of the workpiece 100, the length of the threads, and the specifications of the threads (thread pitch, outer diameter, and root diameter). The chucking pressure is the pressure at which the chucking part chuckings the workpiece. For example, the chucking pressure is calculated using the material of the workpiece 100, the length of the threads, and the specifications of the threads as parameters.

[0048] The terminal device 2 generates the cutting blade rotation speed, workpiece feed rate, and workpiece travel distance based on the material, thread length, and thread specifications of the workpiece 100. The cutting blade rotation speed is the rotation speed of the rotating mechanism 230, which will be described later. The workpiece feed rate is the speed at which the chucked workpiece is moved toward the cutting blade. The workpiece travel distance is the distance the workpiece is moved axially during cutting. The server 3 calculates the cutting height, chucking pressure, cutting blade rotation speed, workpiece feed rate, and workpiece travel distance and transmits them to the cutting control device 8. The cutting height, chucking pressure, cutting blade rotation speed, workpiece feed rate, and workpiece travel distance are included in the machining conditions.

[0049] The cutting control device 8 performs the screw manufacturing process in the same manner as the screw manufacturing process performed by the rolling control device 5 (see Figure 15). In Figure 15, the control unit 8a is used instead of the control unit 5a, the cutting positioning machine 94 is used instead of the rolling positioning machine 50 in step S2, and the screw is manufactured by cutting instead of rolling in step S8. The cutting machine 96 is equipped with a sensor that detects the end position of the workpiece 100. The cutting control device 8 synchronizes the feed amount from the feed mechanism with the rotation speed from the rotation mechanism 230 to form a screw with a desired pitch. Conventionally, multiple feed gears with different numbers of teeth were prepared, and multiple types of cutting blades with multiple teeth and different pitches were prepared, and the gear was selected according to the pitch of one cutting blade. However, since the rotation speed and feed amount are synchronized by the servo mechanism, this adjustment is no longer necessary. The cutting control device 8 moves the workpiece 100 toward the cutting blade by the sum of the detected end position, the distance between the cutting blade and the screw length, to form the screw.

[0050] Figures 18 to 23 are explanatory diagrams illustrating the removal of chips 150 by the removal mechanism 200. The removal mechanism 200 includes a vertical column 201. A pivot 202 extending to the left and right is provided on the vertical column 201. A rotating arm 203 is rotatably mounted on the pivot 202. A support base 204 is provided at the tip of the rotating arm 203. The support base 204 has a support surface extending to the left and right, and a plurality of sliders 205 are provided on this support surface. Rails 206 extending to the left and right are slidably mounted on the sliders 205. A clamp shift cylinder 208 is connected to the sliders 205. The clamp shift cylinder 208 has a rod protruding to the right, and the rod is connected to the right end of the rail 206 via a connecting plate 207. The rod moves in the left and right direction. The rail 206 moves left and right as the rod moves left and right.

[0051] A rotating cylinder 209 is mounted on the vertical column 201 above and behind the clamp shift cylinder 208. The rod of the rotating cylinder 209 extends in a direction intersecting the rail 206 and is connected to the side of the clamp shift cylinder 208. By extending and retracting the rod, the clamp shift cylinder 208, rail 206, slider 205, and rotating arm 203 rotate around the pivot 202.

[0052] A clamp unit 210 is provided at the left end of the rail 206. The clamp unit 210 has a support frame 211, and the right side of the support frame 211 is fixed to the left end of the rail 206. A link 214 is provided on the support frame 211. A front claw 212 and a rear claw 213 are connected to the link 214. A clamping cylinder 215 is provided on the support frame 211. The rod of the clamping cylinder 215 protrudes forward. The rod is connected to the link 214, and as the rod extends, the front claw 212 and the rear claw 213 move closer to each other, and as the rod retracts, the front claw 212 and the rear claw 213 move further apart.

[0053] A hammering unit 217 is provided on the left side of the vertical column 201. The hammering unit 217 is connected to the vertical column 201 via a connecting member 216. The hammering unit 217 comprises a link mechanism 218, a hammering cylinder 220, and a chip hammer 219 (see Figures 18 to 20). The link mechanism 218 is fixed to the connecting member 216. The chip hammer 219 is connected to the upper part of the link mechanism 218. The hammering cylinder 220 is connected to the lower part of the link mechanism 218. The rod of the hammering cylinder 220 protrudes upward, and the vertical movement of the rod causes the chip hammer 219 to move in a direction toward the chip removal plate 223 and in a direction toward the chip removal plate 223.

[0054] A chip removal plate 223 is provided on the vertical column 201, perpendicular to the left-right direction. The chip removal plate 223 has a hole 223a that penetrates from left to right. A guide pipe cylinder 221 is provided on the vertical column 201. The rod of the guide pipe cylinder 221 protrudes to the left. The tip of the rod is connected to a guide plate 222 that extends in a direction intersecting the left-right direction. A through hole 222a is formed in the guide plate 222 that penetrates from left to right. A guide pipe 222b protrudes to the left from the through hole 222a. The internal spaces of the guide pipe 222b and the through hole 222a are connected. When the rod of the guide pipe cylinder 221 extends, the guide pipe 222b is inserted into the hole 223a from the right side. When the rod of the guide pipe cylinder 221 retracts, the guide pipe 222b comes out of the hole 223a and moves to the right side. In the initial state, the guide pipe 222b is inserted into the hole 223a. A cutting blade 231 and a rotating mechanism 230 are provided on the left side of the chip removal plate 223. The cutting blade 231 is mounted on the rotating mechanism 230 and rotates with the left-right direction as the axis of rotation by the rotating mechanism 230.

[0055] As shown in Figure 18, the workpiece 100 is inserted into the guide pipe 222b from the right side and processed by the rotating cutting blade 231 to produce a screw 101. The cutting by the cutting blade 231 generates helical chips 150 from the workpiece 100. The chips 150 become entangled in the guide pipe 222b. The cutting machine 96 has a mechanism (not shown) that moves the cutting blade 231 closer to or further away from the workpiece 100. During cutting, the cutting control device 8 uses the aforementioned mechanism to move the cutting blade 231 away from the workpiece 100 for a short time to thin the chips 150 and stop the generation of chips 150. After that, the cutting blade 231 is rotated in the reverse direction for a short time to restart cutting, and this is repeated. As shown in Figure 19, when cutting is complete, the rotary cylinder 209 is driven, causing the rail 206 and clamp unit 210 to rotate around the pivot 202, with the front claw 212 positioned in front of the guide pipe 222b and the rear claw 213 positioned behind the guide pipe 222b. The rod of the clamping cylinder 215 extends, and the front claw 212 and rear claw 213 hold down the chips 150.

[0056] As shown in Figure 20, a rod extends to the right from the clamp shift cylinder 208, and the rail 206 and clamp unit 210 move to the right. The front jaws 212 and rear jaws 213 move the chips 150 toward the chip removal plate 223. As shown in Figure 21, the rod of the clamp cylinder 215 retracts, and the front jaws 212 and rear jaws 213 move away from the chips 150. The chucking part moves to the right, and the screw 101 is removed from the guide pipe 222b.

[0057] As shown in Figure 22, the rod of the guide pipe cylinder 221 retracts, and the guide pipe 222b exits the hole 223a. The chips 150 entangled in the guide pipe 222b are scraped off by the chip removal plate 223 and fall. As shown in Figure 23, the striking cylinder 220 is driven, and the chip striking 219 approaches the chip removal plate 223. Any remaining chips 150 on the chip removal plate 223 are dropped downwards by the chip striking 219. The rotating cylinder 209 is also driven, and the clamp unit 210 returns to its original position. By removing the chips 150, it is possible to prevent chips 150 from remaining on the cutting blade 231 and adversely affecting the cutting of the workpiece 100.

[0058] Alternatively, instead of providing the guide pipe 222b, the chips 150 that have become entangled with the workpiece 100 or the screw 101 may be scraped off by the chip removal plate 223.

[0059] The embodiments disclosed herein should be considered in all respects to be illustrative and not restrictive. The technical features described in each embodiment can be combined with each other, and the scope of the present invention is intended to include all modifications within the claims and equivalents thereof. [Explanation of symbols]

[0060] 1. Screw manufacturing system 2. Terminal device 3. Server 4. Thread rolling machine 5. Thread rolling control device 7. Cutting machine 8. Cutting control device 10. Extraction machine 20. Conveyor 40. Length measuring machine 50. Thread rolling positioning machine 80. Thread rolling machine 60. Discharge conveyor 70. Receiving box 90. Crane 91. Extraction machine 92. Conveyor 93. Length measuring machine 94. Cutting positioning machine 96. Cutting machine 95. Discharge conveyor 97. Receiving box

Claims

1. A thread rolling machine that manufactures screws by rolling, A cutting machine that manufactures screws by cutting, A control device that is communicatively connected to the aforementioned rolling apparatus and cutting apparatus and controls the aforementioned rolling apparatus and cutting apparatus. Equipped with, The control device is The system stores the specification information for screws manufactured by rolling and the specification information for screws manufactured by cutting. When processing conditions are requested from the aforementioned thread rolling machine, the specification information of the screw to be manufactured by thread rolling is transmitted to the thread rolling machine. When the cutting device requests processing conditions, the specification information of the screw to be manufactured by cutting is transmitted to the cutting device. The aforementioned thread rolling apparatus generates processing conditions for the threads manufactured by thread rolling based on the specification information of the threads manufactured by thread rolling. The cutting device is a screw manufacturing system that generates machining conditions for screws manufactured by cutting, based on the specification information of the screws to be manufactured by cutting.

2. A thread rolling apparatus for manufacturing screws by thread rolling, A cutting machine that manufactures screws by cutting, A control device that is communicatively connected to the aforementioned rolling apparatus and cutting apparatus and controls the aforementioned rolling apparatus and cutting apparatus. Equipped with, The control device is The system stores the specification information for screws manufactured by rolling and the specification information for screws manufactured by cutting. When processing conditions are requested from the thread rolling apparatus, the processing conditions are generated based on the specification information of the screw to be manufactured by the thread rolling, and the generated processing conditions are transmitted to the thread rolling apparatus. When the cutting device requests machining conditions, the system generates the machining conditions based on the specifications of the screw to be manufactured by the cutting process and transmits the generated machining conditions to the cutting device. Screw manufacturing system.

3. The aforementioned specification information includes the diameter of the screw, The rolling apparatus comprises a rolling control device, a rolling machine for rolling a workpiece, and a rolling positioning machine for positioning the workpiece relative to the rolling machine. The cutting apparatus comprises a cutting control device, a cutting machine for cutting a workpiece, and a cutting positioning machine for positioning the workpiece relative to the cutting machine. The processing conditions include a rolling height, which is the height of the rolling positioning machine that is generated based on the diameter of the workpiece and aligns the position of the workpiece with the position of the rolling machine, and a cutting height, which is the height of the cutting positioning machine that is generated based on the diameter of the workpiece and aligns the position of the workpiece with the position of the cutting machine. When the rolling control device receives the rolling height, it moves the rolling positioning machine vertically so that it reaches the rolling height. When the cutting control device receives the cutting height, it moves the cutting positioning machine vertically so that the cutting height is achieved. The screw manufacturing system according to claim 2.

4. The aforementioned specification information includes the material of the workpiece, the length of the thread, and the specifications of the thread. The processing conditions include the rolling pressure of the thread rolling machine, which is generated based on the material of the workpiece, the length of the thread, and the specifications of the thread, and the chucking pressure of the cutting machine, which is generated based on the material of the workpiece, the length of the thread, and the specifications of the thread, for chucking the workpiece. When the rolling control device receives the rolling pressure, it drives the rolling machine according to the rolling pressure. When the cutting control device receives the chucking pressure, it drives the cutting machine according to the chucking pressure. The screw manufacturing system according to claim 3.

5. The aforementioned specification information includes the material of the workpiece, the length of the thread, and the specifications of the thread. The processing conditions include the rolling time of the thread rolling machine, which is generated based on the material of the workpiece, the length of the thread, and the specifications of the thread, and the rotational speed of the cutting blade of the cutting machine, the feed rate of the workpiece, and the distance traveled by the workpiece, which are generated based on the material of the workpiece, the length of the thread, and the specifications of the thread. When the rolling control device receives the rolling time, it drives the rolling machine according to the rolling time. When the cutting control device receives the rotational speed of the cutting blade of the cutting machine, the feed rate of the workpiece, and the distance the workpiece has traveled, it drives the cutting machine according to the rotational speed of the cutting blade, the feed rate of the workpiece, and the distance the workpiece has traveled. The screw manufacturing system according to claim 3.

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