Simulation program, recording medium, simulation method, and simulation apparatus

Abstract

To provide a simulation program that allows for checking information serving as an indicator of energy consumption.SOLUTION: A simulation program is used for simulating a motion of a press line provided with press devices 1P to 5P for press working a workpiece W. The simulation program includes a step S1 and steps S2 to S4. In step S1, the motion of the press line 1 is generated. In steps S2 to S4, information relating to power consumption of the press line 1 is calculated on the basis of the motion of the press line 1.SELECTED DRAWING: Figure 6

Description

Technical Field

[0001] The present invention relates to a simulation program, a recording medium, a simulation method, and a simulation device.

Background Art

[0002] For example, a tandem press line is used for forming an automobile body. In a tandem press line, a plurality of press devices are installed side by side, and a feeder device (transfer device) for transferring a workpiece is provided between each press device.

[0003] In such a press line, a press line simulator is used to create appropriate forming motions and transfer motions while avoiding interference between the press device and the feeder device (see, for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] In the operation of a conventional press line, the focus has been on how to improve productivity. However, in recent years, with the trend towards carbon neutrality, attention has also been paid to reducing energy consumption.

[0006] An object of the present invention is to provide a simulation program, a recording medium, a simulation method, and a simulation device capable of confirming information serving as an index of energy consumption.

Means for Solving the Problems

[0007] The simulation program relating to the first disclosure is a simulation program for simulating the motion of a press line equipped with a first press device for press-forming a workpiece, and causes a computer to perform a motion generation step and a power consumption information calculation step. The motion generation step generates the motion of the press line. The power consumption information calculation step calculates information regarding the power consumption of the press line based on the motion of the press line.

[0008] The simulation method relating to the second disclosure is a simulation method for simulating the motion of a press line equipped with a first press device for press-forming a workpiece, and comprises a motion generation step and a power consumption information calculation step. The motion generation step generates the motion of the press line. The power consumption information calculation step calculates information regarding the power consumption of the press line based on the motion of the press line.

[0009] The simulation device according to the third disclosure is a simulation device for simulating the motion of a press line equipped with a first press device for press-forming a workpiece, and comprises a motion generation unit and a power consumption information calculation unit. The motion generation unit generates the motion of the press line. The power consumption information calculation unit calculates information regarding the power consumption of the press line based on the motion of the press line. [Effects of the Invention]

[0010] According to the present invention, it is possible to provide a simulation program, recording medium, simulation method, and simulation apparatus that can confirm information that serves as an indicator of energy consumption. [Brief explanation of the drawing]

[0011] [Figure 1] A diagram showing the press lines in the embodiments relating to this disclosure. [Figure 2]A diagram showing the configuration of a press apparatus in an embodiment of the present disclosure. [Figure 3] A diagram showing the configuration of a set of servo motors and a transmission mechanism in an embodiment of the present disclosure. [Figure 4] A perspective view showing the configuration of a feeder device in an embodiment of the present disclosure. [Figure 5] A block diagram showing the configuration of the simulation apparatus in the embodiment of the present disclosure. [Figure 6] A flowchart illustrating the simulation method in the embodiments relating to this disclosure. [Figure 7] (a) to (e) Diagrams showing the motion and workload of the feeder and press devices, (f) Diagram showing the motion of the feeder and press devices and the workload of the press line. [Figure 8] A flowchart illustrating the calculation of work volume in a press machine according to the embodiments of this disclosure. [Figure 9] (a) A diagram showing the slide motion of a press device in an embodiment of the present disclosure; (b) A diagram showing the motion of a servo motor for realizing the motion in Figure 9(a). [Figure 10] (a) A graph showing the change in torque of the servo motor over time, (b) A graph showing the change in work done by the servo motor over time. [Figure 11] This figure shows an example of a display screen shown on the display unit of the simulation device in the embodiment of the present disclosure. [Modes for carrying out the invention]

[0012] The simulation program described in this disclosure is explained below with reference to the drawings. First, we will describe the configuration of the press line that will be simulated using the simulation program of this disclosure.

[0013] (Press line 1) Figure 1 is a schematic diagram showing the configuration of the press line 1 in the embodiment of the present disclosure.

[0014] The press line 1 of the present embodiment performs press working on each press device and conveys the workpiece W by the feeder device between the press devices. The conveyance direction of the workpiece W is illustrated as X.

[0015] The press line 1 is a tandem press line, and includes a plurality of press devices 1P, 2P, 3P, 4P, 5P, a plurality of feeder devices LD, 1F, 2F, 3F, 4F, UL, and a press line control device 4. These plurality of press devices 1P, 2P, 3P, 4P, 5P, the plurality of feeder devices LD, 1F, 2F, 3F, 4F, UL, and the press line control device 4 are connected to the same factory power supply.

[0016] (Press Device 2) In the press line 1 of the present embodiment, as shown in FIG. 1, the press devices 1P, 2P, 3P, 4P, 5P are arranged along the workpiece conveyance direction X. The press devices 1P, 2P, 3P, 4P, 5P have the same configuration. The press line 1 of the present embodiment includes five press devices. Any one of the press devices 1P, 2P, 3P, 4P, 5P corresponds to an example of the first press device, and another one corresponds to an example of the second press device.

[0017] Since the press devices 1P, 2P, 3P, 4P, 5P have the same configuration, the configuration will be described by taking the press device 1P as an example. FIG. 2 is a schematic diagram showing the configuration of the press device 1P. The press device 1P mainly includes a bed 11, an upright 12, a crown 13, a slide 14, a bolster 15, and a slide drive unit 16.

[0018] The bed 11 is embedded in the floor and constitutes the base of the press device 2. The upright 12 is a columnar member, and four are arranged on the bed 11. The four uprights 12 are arranged so as to form the respective vertices of a rectangle in a plan view.

[0019] The crown 13 is supported above the bed 11 by four uprights 12. The slide 14 is suspended below the crown 13 so as to be able to move up and down. An upper die 19a is detachably attached to the lower surface 14s of the slide 14 by a die clamp (not shown). The bolster 15 is located below the slide 14 and on the bed 11. A lower die 19b is placed above the bolster 15.

[0020] The slide drive unit 16 is located on the crown 13 and moves the slide 14, which is located on the underside of the crown 13, up and down.

[0021] (Slide drive unit 16) The slide drive unit 16 is located on the crown 13 and moves the slide 14 up and down. The slide drive unit 16 supports the slide 14 at four points. The slide drive unit 16 has four servo motors 21 that are the drive source and four transmission mechanisms 22 that transmit the drive of each servo motor 21 to the slide. Although only two servo motors 21 and two transmission mechanisms 22 are shown in Figure 2, two more servo motors 21 and two more transmission mechanisms 22 are located further back in the page.

[0022] Each transmission mechanism 22 includes a first reduction gear 23 and a second reduction gear 24 that reduce the rotation of each servo motor 21, a lifting unit 25 that converts the reduced rotational motion into reciprocating motion in the vertical direction, and a plunger 26 whose lower end is fixed to the slide 14 and moves the slide 14 in the vertical direction.

[0023] Figure 3 shows the configuration of a set of servo motors 21 and a transmission mechanism 22. The servo motor 21 is mounted on the crown 13 such that its drive shaft 21a is positioned horizontally.

[0024] The first reduction gear 23 is a constant-speed reduction gear and is connected to the drive shaft 21a of the servo motor 21. The first reduction gear 23 has a large pulley 23a, a first pinion 23b, a first gear 23c, a second pinion 23d, a second gear 23e, and a third pinion 23f. The rotation of a small pulley 28 fixed to the drive shaft 21a of the servo motor 21 is transmitted to the large pulley 23a by a belt 29. The first pinion 23b is integrally mounted on the large pulley 23a. The first gear 23c meshes with the first pinion 23b. The second pinion 23d is integrally mounted on the first gear 23c. The second gear 23e meshes with the second pinion 23d. The third pinion 23f is integrally mounted on the second gear 23e. The third pinion 23f meshes with a large-diameter helical gear 24a located on the outer circumference of the second reduction gear 24.

[0025] The second reduction gear 24 is a Whitworth reduction gear that reduces the rotational speed during one rotation so that the rotational speed is uneven, and transmits power to the eccentric shaft 25a of the lifting section 25. The second reduction gear 24 has a helical gear 24a, a lever 24b, and a connecting member 24c. The helical gear 24a is ring-shaped and is located on the outer circumference of the second reduction gear 24. The lever 24b is fixed to the eccentric shaft 25a, which is provided projecting horizontally from the frame of the crown 13. The connecting member 24c connects the lever 24b and the inner circumference of the helical gear 24a. The rotation center of the helical gear 24a is located vertically above the axis of the eccentric shaft 25a.

[0026] The lifting section 25 includes an eccentric shaft 25a, an eccentric drum 25b, and a connecting rod 25c. The eccentric shaft 25a is pivotally supported on both sides of the eccentric drum 25b (the front and back sides in the direction perpendicular to the plane of the paper in Figure 3) by the frame of the crown 13. The eccentric drum 25b is formed in the shape of a disc that is eccentric with respect to the eccentric shaft 25a, and rotates eccentrically with the rotation of the eccentric shaft 25a. The connecting rod 25c is connected to the eccentric drum 25b. A plunger 26 is connected below the connecting rod 25c, and a slide 14 is attached below the plunger 26.

[0027] A plunger holder 27 is fixed to the underside of the crown 13, guiding the plunger 26 in the vertical direction. The plunger holder 27 can also be said to restrict the horizontal movement of the plunger 26.

[0028] As the eccentric rotation of the eccentric drum 25b of the lifting section 25, as described above, causes the connecting rod 25c to swing, the plunger 26 moves vertically, and the slide 14 moves vertically. The vertical movement of the slide 14 causes the workpiece W to be pressed by the upper die 19a and the lower die 19b.

[0029] (Feeder device 3) In the press line 1 of this embodiment, as shown in Figure 1, the feeder devices LD, 1F, 2F, 3F, 4F, and UL are arranged along the workpiece transport direction X. The configuration of the feeder devices LD, 1F, 2F, 3F, 4F, and UL is the same. The press line 1 of this embodiment is equipped with six feeder devices. One of the feeder devices LD, 1F, 2F, 3F, 4F, and UL corresponds to an example of the first transport device.

[0030] As shown in Figure 1, feeder device LD is located upstream of press device 1P. Feeder device LD delivers workpieces W to press device 1P. Feeder device 1F is located between press device 1P and press device 2P. Feeder device 1F transports workpieces W from press device 1P to press device 2P. Feeder device 2F is located between press device 2P and press device 3P. Feeder device 2F transports workpieces W from press device 2P to press device 3P. Feeder device 3F is located between press device 3P and press device 4P. Feeder device 3F transports workpieces W from press device 3P to press device 4P. Feeder device 4F is located between press device 4P and press device 5P. Feeder device 4F transports workpieces W from press device 4P to press device 5P. Feeder device UL is located downstream of press device 5P. The feeder device UL unloads the workpiece W from the press device 5P.

[0031] Since the configurations of feeder units LD, 1F, 2F, 3F, 4F, and UL are the same, we will explain the configuration using feeder unit 1F as an example.

[0032] Figure 4 is a perspective view showing the configuration of feeder device 1F. Feeder device 1F has a first drive unit 31 located on one side in the width direction Y, and a second drive unit 32 located on the other side in the width direction Y. The first drive unit 31 has a guide rail 41 extending in the transport direction X. The second drive unit 32 has a guide rail 41' extending in the transport direction X. In Figure 4, the guide rails 41 and 41' are shown as dashed lines. The guide rails 41 and 41' are configured to be immovable. In feeder device 1F, the guide rails 41 and 41' are arranged from press unit 1P to press unit 2P. In feeder device LD, the guide rails 41 and 41' are located upstream of press unit 1P. In feeder devices 2F to 4F, similar to feeder device 1F, the guide rails 41 and 41' are located between adjacent press units. In the feeder device UD, the guide rails 41 and 41' are located downstream of the press device 5P. The guide rails 41 and 41' are fixed to the uprights 12 of the press devices 1P to 5P, for example.

[0033] The feeder device 1F further comprises a crossbar 33. The crossbar 33 extends in the width direction Y. The crossbar 33 is positioned below the guide rails 41, 41'. One end of the crossbar 33 in the width direction Y is supported by the first drive unit 31. The other end of the crossbar 33 in the width direction Y is supported by the second drive unit 32. The crossbar 33 is stretched between the first drive unit 31 and the second drive unit 32.

[0034] The crossbar 33 holds the workpiece W (see Figure 2) in the middle section between one end and the other. A transport tool (not shown) for holding the workpiece W is attached to the crossbar 33. An example of a transport tool is a vacuum cup that sucks up the workpiece W. In adjacent press machines 2, after the press processing of the workpiece in the upstream press machine 2 is completed, the crossbar 33 enters between the upper die 19a and the lower die 19b and holds the workpiece W. With the crossbar 33 holding the workpiece W, the first drive unit 31 and the second drive unit 32 move the crossbar 33 along a predetermined operating trajectory, thereby transporting the workpiece W from the upstream press machine 2 to the downstream press machine 2. The crossbar 33 enters between the upper die 19a and the lower die 19b of the downstream press machine 2 and releases its grip on the workpiece W, thereby handing the workpiece W over to the downstream press machine 2.

[0035] The first drive unit 31 has a base portion 42. The base portion 42 is supported by the guide rail 41. The base portion 42 is attached to the lower surface of the guide rail 41. The base portion 42 is suspended from the guide rail 41. In this embodiment, the base portion 42 is attached to the lower surface of the guide rail 41, but it may also be attached to the upper surface or side surface of the guide rail 41.

[0036] The base portion 42 is configured to be movable in the transport direction X along the guide rail 41. The base portion 42 moves relative to the guide rail 41 when a driving force is transmitted to it from a drive source (not shown), such as a servo motor. The base portion 42 reciprocates between the two ends of the guide rail 41. The power transmission device that transmits the driving force to the base portion 42 may include a rack and pinion mechanism, a timing belt, or a ball screw. The drive source that moves the base portion 42 may also be a linear motor.

[0037] The first drive unit 31 has a parallel mechanism 43. The parallel mechanism 43 is supported by a base portion 42. The parallel mechanism 43 includes a first arm portion 44 and a second arm portion 45 that are in parallel with each other.

[0038] The first arm portion 44 includes a lever 441 and a link 442. The lever 441 is mounted on the base portion 42 so as to be rotatable relative to the base portion 42. The lever 441 has a base end attached to the base portion 42 and a tip opposite the base end. The link 442 is mounted on the tip of the lever 441 so as to be rotatable relative to the lever 441. The link 442 has a base end attached to the tip of the lever 441 and a tip opposite the base end. The end of the crossbar 33 is attached to the tip of the link 442. The crossbar 33 is supported at the tip of the parallel mechanism 43.

[0039] The second arm section 45 includes a lever 451 and a link 452. The lever 451 is mounted on the base section 42 so as to be rotatable relative to the base section 42. The lever 451 has a base end attached to the base section 42 and a tip opposite the base end. The link 452 is mounted on the tip of the lever 451 so as to be rotatable relative to the lever 451. The link 452 has a base end attached to the tip of the lever 451 and a tip opposite the base end. The tip of the link 452 is not connected to the crossbar 33 but is connected to the link 442. The tip of the link 452 may be directly connected to the crossbar 33.

[0040] The first drive unit 31 includes a first motor 46 and a second motor 47. The first motor 46 and the second motor 47 are, for example, servo motors. The first motor 46 and the second motor 47 generate a driving force to drive the parallel mechanism 43.

[0041] The first motor 46 and the second motor 47 are mounted on the base portion 42. The first motor 46 and the second motor 47 are positioned on the opposite side of the base portion 42 from the first arm portion 44 and the second arm portion 45. The base portion 42 is positioned between the first arm portion 44 and the first motor 46, and between the second arm portion 45 and the second motor 47.

[0042] The first motor 46 applies a driving force to the first arm 44 to move it relative to the base 42. The second motor 47 applies a driving force to the second arm 45 to move it relative to the base 42.

[0043] The parallel mechanism 43 is driven by the first motor 46 and the second motor 47 and is operable in a plane defined by the transport direction X and the vertical direction. The operation of the parallel mechanism 43 changes the relative position of the crossbar 33 attached to the end of the link 442 with respect to the base 42.

[0044] The second drive unit 32 has the same configuration as the first drive unit 31, but is arranged in a 180° inverted configuration. As shown in Figure 4, each component of the second drive unit 32 is assigned a reference number that is the same as the reference number assigned to the corresponding component of the first drive unit 31, with an apostrophe (') added to it. A detailed explanation of the configuration of the second drive unit 32 is omitted as it overlaps with the explanation of the first drive unit 31.

[0045] (Press line control device 4) As shown in Figure 1, the press line control device 4 controls the press devices 1P, 2P, 3P, 4P, 5P and the feeder devices LD, 1F, 2F, 3F, 4F, UL.

[0046] The press line control device 4 includes a processor and memory. The processor is, for example, a CPU (Central Processing Unit). Alternatively, the processor may be a different processor from the CPU. The processor performs processing for controlling the press devices 1P to 5P and the feeder devices LD, 1F, 2F, 3F, 4F, and UL according to the press line motion program stored in memory. The memory includes non-volatile memory such as ROM (Read Only Memory) and volatile memory such as RAM (Random Access Memory). The memory may also include auxiliary storage devices such as HDD (Hard Disk Drive) or SSD (Solid State Drive). Memory is an example of a non-transitory computer-readable recording medium. The press line motion program stored in memory is created by the simulation device 5, which will be described later. The press line control device 4 is connected to the simulation device 5 by wire or wireless so that it can receive data from the simulation device 5.

[0047] The press line control device 4 controls the press devices 1P to 5P. Specifically, the press line control device 4 controls the press work by driving the four servo motors 21, each of which is provided in press devices 1P to 5P, by transmitting commands to the servo motors 21.

[0048] The press line control device 4 controls the feeder devices LD, 1F, 2F, 3F, 4F, and UL. Specifically, the press line control device 4 drives the servo motors to transport the workpiece W by sending commands to the servo motors that move the first motor 46, second motor 47, and first drive unit 31 of each of the feeder devices LD, 1F, 2F, 3F, 4F, and UL in the transport direction X, as well as the servo motors that move the first motor 46', second motor 47', and second drive unit 32 in the transport direction X.

[0049] (Simulation device 5) Figure 5 is a block diagram showing the configuration of the simulation device 5. The simulation device 5 includes a simulation unit 51, an input unit 52, a display unit 53, and a communication unit 54. The simulation unit 51 generates the motion of the press line 1 and calculates the power consumption of the press line 1 during that motion.

[0050] The input unit 52 includes, for example, a keyboard and mouse, and the operator inputs various settings while looking at the display unit 53. The operator uses the input unit 52 to input data for generating the motion of the press line 1. This data may include shape data of the molds (upper mold 19a and lower mold 19b), shape data of the workpiece W, shape data of the workpiece transport tool, or the production speed of the press line 1.

[0051] The simulation unit 51 is, for example, a workstation (an example of a computer). The simulation unit 51 includes a processor and memory. The processor is, for example, a CPU (Central Processing Unit). Alternatively, the processor may be a different processor from the CPU. The processor generates the motion of the press line 1 according to a program stored in memory and performs the process of calculating the power consumption in that motion. The memory includes non-volatile memory such as ROM (Read Only Memory) and volatile memory such as RAM (Random Access Memory). The memory may also include auxiliary storage devices such as HDD (Hard Disk Drive) or SSD (Solid State Drive). The memory is an example of a non-transitory computer-readable recording medium.

[0052] The simulation unit 51 includes a motion generation unit 51a, a power consumption calculation unit 51b (an example of a power consumption information calculation unit), and a display control unit 51c. The simulation unit 51 realizes the functions of the motion generation unit 51a, the power consumption calculation unit 51b, and the display control unit 51c by executing a program stored in memory by the processor.

[0053] The memory stores multiple slide motion data for the press device 2 and multiple feeder motion data for the feeder device 3. Based on the data input to the input unit 52, the motion generation unit 51a considers the interference between the workpiece W and the mold and generates the motion of the press line 1 from the slide motion data and feeder motion data stored in the memory. In this embodiment, the motion generation unit 51a generates press line motion with a phase difference between the multiple press devices 2. As will be explained later in Figures 7(a) to 7(e), the phase difference is that the position of the slide 14 at the same time differs among the multiple press devices 2.

[0054] The power consumption calculation unit 51b calculates the power consumption in the press line motion generated by the motion generation unit 51a. The power consumption calculation unit 51b has a first calculation unit 51d and a second calculation unit 51e. The first calculation unit 51d calculates the amount of work done in each of the press devices 1P to 5P and feeder devices LD, 1F, 2F, 3F, 4F, and UL in the press line motion generated by the motion generation unit 51a. As will be explained in detail in Figure 9 below, the first calculation unit 51d calculates the amount of work done by the servo motors that execute the generated press line motion for the press device 2. The servo motors of the press device 2 are, for example, four servo motors 21. The first calculation unit 51d calculates the amount of work done by the servo motors that execute the generated press line motion for the feeder device 3. The servo motors of the feeder device 3 include, for example, the servo motors that move the first motor 46, the second motor 47, and the first drive unit 31 along the transport direction X, and the servo motors that move the first motor 46', the second motor 47', and the second drive unit 32 along the transport direction X.

[0055] The second calculation unit 51e calculates the power consumption per workpiece on press line 1 from the amount of work done in each of the press devices 1P to 5P and the feeder devices LD, 1F, 2F, 3F, 4F, and UL. Here, the power consumption per workpiece is the power consumption per cycle (one period).

[0056] The display control unit 51c displays the power consumption of the press line 1, calculated by the simulation unit 51, on the display unit 53.

[0057] The display unit 53 is, for example, a monitor. The display unit 53 displays the power consumption of the press line 1 calculated in the simulation unit 51 based on the control signal from the display control unit 51c. The display unit 53 may also display the power consumption of the press devices 1P to 5P and the feeder devices LD, 1F, 2F, 3F, 4F, and UL, along with the power consumption of the press line 1.

[0058] The communication unit 54 transmits the generated press line motion and power consumption to the press line control device 4. The communication unit 54 is connected to the press line control device 4 by wire or wireless connection. Alternatively, the press line motion generated by the simulation device 5 may be transferred to the press line control device 4 via a storage medium such as a USB memory stick.

[0059] (Simulation method) Next, the simulation method will be described. The program of this disclosure is a program in which a computer performs all or some of the steps of the following simulation method.

[0060] Figure 6 is a flowchart illustrating the simulation method.

[0061] First, in step S1 (an example of a motion generation step), the motion generation unit 51a generates the motion of the press line 1. Based on the data input to the input unit 52, the motion generation unit 51a considers the interference between the workpiece W and the mold and generates the motion of the press line 1 from the slide motion data and feeder motion data stored in memory.

[0062] Figures 7(a) to 7(e) show the motion of feeder unit LD, press unit 1P, feeder unit 1F, press unit 2P, and feeder unit 2F. For the sake of clarity, the motion of feeder units 3F, 4F, UL, and press units 3P, 4P, and 5P is omitted.

[0063] Figure 7(a) shows graph 61a of the motion of feeder device LD in the generated press line motion. Graph 61a is shown as a solid line. Below graph 61a, graph 61b, showing the change in the amount of work done by feeder device LD over time, is shown as a solid line. Figure 7(b) shows graph 62a of the motion of press device 1P in the generated press line motion. Graph 62a is shown as a dashed line. Below graph 62a, graph 62b, showing the change in the amount of work done by press device 1P over time, is shown as a solid line. Figure 7(c) shows graph 63a of the motion of feeder device 1F in the generated press line motion. Graph 63a is shown as a dashed line. Below graph 63a, graph 63b, showing the change in the amount of work done by feeder device 1F over time, is shown as a solid line. Figure 7(d) shows graph 64a of the motion of press device 2P in the generated press line motion. Graph 64a is shown as a dashed line. Below graph 64a, graph 64b, showing the time variation of the work rate of press device 2P, is shown as a solid line. Figure 7(e) shows graph 65a of the motion of feeder device 2F in the generated press line motion. Graph 65a is shown as a dashed line. Below graph 65a, graph 65b, showing the time variation of the work rate of feeder device 2F, is shown as a solid line.

[0064] In the diagrams showing the motion of the feeder devices LD, 1F, and 2F, shown in Figures 7(a), 7(c), and 7(e), the vertical axis indicates the position of the crossbar 33 in the transport direction X, and the horizontal axis indicates time. Note that in the feeder devices, the crossbar 33 is moved not only in the transport direction X but also in the vertical direction, but the amount of movement in the vertical direction is small compared to the movement in the transport direction, and therefore has little effect on the workload of the device described later. In the diagrams showing the motion of the press devices 1P and 2P, shown in Figures 7(b) and 7(d), the vertical axis indicates the vertical position of the slide 14, and the horizontal axis indicates time.

[0065] Press devices 1P to 5P repeat a predetermined motion in each cycle. Feeder devices LD, 1F, 2F, 3F, 4F, and UL repeat a predetermined motion in each cycle.

[0066] Let's explain the timings in Figures 7(a) to (e). If we let t1 be the time when the first cycle of motion of feeder device LD begins, then at time t2, the first cycle of motion of feeder device 1F begins after the motion of feeder device LD has started. After time t2, at time t3, the first cycle of motion of press device 1P begins. After time t3, at time t4, the first cycle of motion of feeder device 2F begins. After time t4, at time t5, the first cycle of motion of press device 2P begins.

[0067] Furthermore, at time t11, the first motion cycle of feeder device LD ends and the second motion cycle begins. After time t11, at time t21, the first motion cycle of feeder device 1F ends and the second motion cycle begins. After time t21, at time t31, the first motion cycle of press device 1P ends and the second motion cycle begins. After time t31, at time t41, the first motion cycle of feeder device 2F ends and the second motion cycle begins. After time t41, at time t51, the first motion cycle of press device 2P ends and the second motion cycle begins. The duration of one motion cycle for each of the press devices 1P-5P and feeder devices LD, 1F, 2F, 3F, 4F, and UL is the same. In Figures 7(a) to 7(e), the time interval ΔT is the same for the intervals t1 to t11, t2 to t21, t3 to t31, t4 to t41, and t5 to t51.

[0068] Each of the press devices 1P to 5P and the feeder devices LD, 1F, 2F, 3F, 4F, and UL repeats a predetermined motion with a period ΔT, thereby processing the workpiece W sequentially in press devices 1P to 5P while being conveyed in the conveying direction X by the feeder devices LD, 1F, 2F, 3F, 4F, and UL.

[0069] As can be seen from Figures 7(b) and 7(d), the timing at which the motion cycle of press device 1P begins is different from the timing at which the motion cycle of press device 2P begins. In other words, there is a phase difference between the motion of press device 1P and the motion of press device 2P. As described above, the phase difference means that the position of the slide 14 at the same time is different among press devices 1P to 5P. As shown in Figures 7(b) and 7(d), at the time when the slide 14 of press device 1P is moving downward from the top dead center, the slide 14 of press device 2P has started to move downward from the top dead center. Thus, in this embodiment, a phase difference is provided between multiple press devices 1P to 5P. Note that a phase difference is not required between all press devices 1P to 5P, and a phase difference may be provided between at least two press devices. Furthermore, while it is common to operate with a phase difference between presses in this way to ensure high productivity, it is not always necessary to provide a phase difference.

[0070] Returning to Figure 6, in step S2 (an example of the first calculation step), the first calculation unit 51d calculates the amount of work done in the press devices 1P to 5P and the feeder devices LD, 1F, 2F, 3F, 4F, and UL. Figure 8 is a flowchart showing the calculation of the amount of work done in press device 2.

[0071] In the work rate calculation, inverse kinematics is performed first in step S11. In inverse kinematics, the work rate is calculated from the motion. The simulation unit 51 stores the specifications of the mechanisms of the press devices 1P to 5P. The specifications include the reduction ratio of the servo motor 21, the length of the links and connecting rods, and the eccentric axis of the drum.

[0072] The first calculation unit 51d calculates the motion of the servo motor to execute the slide motion in the press line motion generated by the motion generation unit 51a, based on the specifications information of the mechanism of the press device.

[0073] Figure 9(a) shows the slide motion of press device 1P. Specifically, Figure 9(a) shows graph 61a (thick solid line) showing the change in the slide position of press device 1P over time, graph 61c (dashed line) showing the change in slide speed over time, and graph 61d (thin solid line) showing the change in slide acceleration over time. The horizontal axis of the graphs in Figure 9(a) represents time. The vertical axis of Figure 9(a) represents the vertical position of the slide for graph 61a, the slide speed for graph 61c, and the slide acceleration for graph 61d. Note that graphs 61c and 61d can be calculated from graph 61a.

[0074] Figure 9(b) is a diagram showing the motion of the servo motor 21 to realize the motion shown in Figure 9(a). The first calculation unit 51d calculates the motion of the servo motor based on the slide motion shown in Figure 9(a) and the specifications information of the press device mechanism. Figure 9(b) shows graph 61e (thick solid line) showing the change in angle of the servo motor 21 over time, graph 61f (dashed line) showing the change in angular velocity of the servo motor 21 over time, and graph 61g showing the change in angular acceleration of the servo motor 21 (thin solid line) over time.

[0075] Returning to the work calculation in Figure 8, in step S12, the first calculation unit 51d calculates the torque of the servo motor when executing the calculated servo motor motion. The first calculation unit 51d calculates the torque of the servo motor based on the servo motor motion, device parameters, mold parameters, and molding load conditions. Device parameters include the moment of inertia of the gears and drum used in the transmission mechanism 22. Mold parameters include the mass of the upper mold 19a and the pressure of the balancer. Molding load conditions include the molding load, die cushion load, and die cushion stroke. Figure 10(a) shows a graph 61h of the change in the servo motor torque over time. In Figure 10(a), the vertical axis represents torque and the horizontal axis represents time.

[0076] Next, in step S13, the first calculation unit 51d calculates the amount of work done by the servo motor. The amount of work done by the servo motor can be determined by the product of torque and each speed. Figure 10(b) shows a graph 61i of the change in the amount of work done by the servo motor over time. In Figure 10(b), the vertical axis represents the amount of work done, and the horizontal axis represents time. The servo motor performs both regenerative and motor operation. In Figures 10(a) and 10(b), the torque during motor operation is a positive value, and the torque during regenerative operation is a negative value. When calculating the power consumption from the work of each device in order to display the power consumption of each device shown in Figure 11, which will be described later, in this embodiment only the power consumption during motor operation is calculated, and the amount of work done during regenerative operation is considered to be 0 and is not taken into account. If a power storage device is provided, the power storage during regenerative operation may also be taken into consideration.

[0077] In this embodiment, the press device 1P is equipped with, for example, four servo motors 21. Steps S11 to S13 are performed for each of the four servo motors 21, and the total work done by the press device 1P can be calculated by summing the work done by all the servo motors. The work done by press devices 2P to 5P is calculated in the same way as that of press device 1P.

[0078] Furthermore, the amount of work is calculated for each of the feeder devices LD, 1F, 2F, 3F, 4F, and UL. Each of the feeder devices LD, 1F, 2F, 3F, 4F, and UL is equipped with a servo motor (not shown) that moves the first motor 46, the second motor 47, and the first drive unit 31 in the transport direction X, as well as a servo motor (not shown) that moves the first motor 46', the second motor 47', and the second drive unit 32 in the transport direction X. Therefore, by calculating the amount of work for each of these servo motors and summing up the amount of work for all the servo motors, the amount of work for each of the feeder devices LD, 1F, 2F, 3F, 4F, and UL can be calculated. As mentioned above, the amount of work done by the first motor 46 and the second motor 47 that move the crossbar 33 up and down is small compared to the amount of work done by the servo motor that moves the first drive unit 31 in the transport direction X and the servo motor that moves the second drive unit 32 in the transport direction X, so it is ignored here.

[0079] As described above, Figure 7(a) shows graph 61b of the change in workload of feeder device LD over time. Figure 7(b) shows graph 62b of the change in workload of press device 1P over time. Figure 7(c) shows graph 63b of the change in workload of feeder device 1F over time. Figure 7(d) shows graph 64b of the change in workload of press device 2P over time. Figure 7(e) shows graph 65b of the change in workload of feeder device 2F over time.

[0080] As described above, in step S2, the amount of work done in each of the press devices 1P to 5P and the feeder devices LD, 1F, 2F, 3F, 4F, and UL is calculated.

[0081] Returning to the simulation method in Figure 6, in step S3, the second calculation unit 51e calculates the workload of press line 1 by summing the workloads of each of the press devices 1P to 5P and the feeder devices LD, 1F, 2F, 3F, 4F, and UL. Figure 7(f) is a graph 66b showing the time change of the workload obtained by summing the workloads of each of the press devices 1P to 5P and the feeder devices LD, 1F, 2F, 3F, 4F, and UL (graphs 61b to 65b). Graphs 61a to 65a are also shown in Figure 7(f).

[0082] Since the press machines 1P to 5P and the feeder machines LD, 1F, 2F, 3F, 4F, and UL are connected to the same factory power supply, the regenerated power from any of these machines can be used to power other machines operating at the same time. For example, by adding up the work rate graphs of each machine (for example, the work rate graphs 61b to 65b shown in Figures 7(a) to 7(e)), the regenerated work rate from one machine can be used to offset the power rate of the other machines, and the total work rate can be calculated.

[0083] In step S4, the second calculation unit 51e calculates the power consumption per product (workpiece W) by calculating the amount of work done for one cycle of the press line 1. Specifically, the second calculation unit 51e calculates the amount of work done in a time interval ΔT of one cycle from the total amount of work and determines the power consumption. In Figure 7(f), the interval from time t4 to t41 is shown, but the amount of work done for one cycle of the press line 1 is the same for any interval of time ΔT, not limited to this time. Note that in the summed amount of work (graph 66), the torque during powered operation is a positive value, and the torque during regenerative operation is a negative value. In this embodiment, when calculating the power consumption from the summed amount of work, only the power consumption during powered operation is calculated, and the amount of work during regenerative operation is considered to be 0 and is not taken into account. If a power storage device is provided, the power storage during regenerative operation may also be taken into consideration. In addition, in the simulation method shown in Figure 6, steps S2, S3 and S4 correspond to an example of a power consumption information calculation step. Steps S3 and S4 correspond to an example of the second calculation step.

[0084] Next, in step S5 (an example of a display step), the display control unit 51c causes the display unit 53 to display the power consumption per product (workpiece W).

[0085] Figure 11 shows an example of the display screen 70 shown on the display unit 53. The display screen 70 shows the power consumption of the entire press line 1 per product (an example of the display power of the press line) in the display area 70a. In Figure 11, the display area 70a shows, for example, 1100W / shot.

[0086] In Figure 11, the power consumption per cycle of feeder device LD is shown in display section 70b. The power consumption per cycle of feeder device 1F is shown in display section 70c. The power consumption per cycle of feeder device 2F is shown in display section 70d. The power consumption per cycle of feeder device 3F is shown in display section 70e. The power consumption per cycle of feeder device 4F is shown in display section 70f. The power consumption per cycle of feeder device UL is shown in display section 70g. Note that both the power consumption per cycle and the power consumption per product are expressed in W / shot.

[0087] Furthermore, in Figure 11, the power consumption per cycle of press device 1P is shown in display section 70h. The power consumption per cycle of press device 2P is shown in display section 70i. The power consumption per cycle of press device 3P is shown in display section 70j. The power consumption per cycle of press device 4P is shown in display section 70k. The power consumption per cycle of press device 5P is shown in display section 70l.

[0088] In this embodiment, because there is a phase difference between the press devices 2, the power consumption of press line 1 per product (70a) is lower than the simple sum of the power consumption of each device (70b to 70l). In each of the press devices 1P to 5P and the feeder devices LD, 1F, 2F, 3F, 4F, and UL, power consumption is calculated by assuming zero power due to regeneration when determining power consumption from the amount of work. On the other hand, since the press devices 1P to 5P and the feeder devices LD, 1F, 2F, 3F, 4F, and UL are connected to the same factory power supply, the power regenerated by any of the devices can be used for other devices that are operating at the same time. Thus, in press line 1, the power consumption is calculated by offsetting the operation of other devices with the regenerated power generated by any of the devices, so the power consumption of press line 1 per product is lower than the simple sum of the power consumption of each device.

[0089] If no phase difference is provided between press units 1P to 5P, it is conceivable that the regenerative power from feeder units LD, 1F, 2F, 3F, 4F, and UL could be used for the press units. However, since the power consumption of feeder units LD, 1F, 2F, 3F, 4F, and UL is smaller than that of press units 1P to 5P, providing a phase difference between press units 1P to 5P can reduce power consumption.

[0090] As described above, the simulation device of this embodiment can display the power consumption of the press line in the generated press line motion, allowing the operator to regenerate or adjust the press line motion while checking the power consumption.

[0091] (Features, etc.) The simulation program of this embodiment is a simulation program that simulates the motion of a press line equipped with press devices 1P to 5P for press processing a workpiece W, and causes a computer to execute steps S1 and S2 to S4. In step S1, the motion of press line 1 is generated. In steps S2 to S4, information regarding the power consumption of press line 1 is calculated based on the motion of press line 1.

[0092] Therefore, it is possible to generate press line motion with reduced power consumption.

[0093] The simulation program of this embodiment further includes step S5 (an example of a display step) which displays information regarding the calculated power consumption of the press line.

[0094] This allows the operator to generate motion for press line 1 while checking the displayed power consumption information, thereby generating press line motion with reduced power consumption. The power consumption information includes power consumption, electricity cost, reduction in power consumption relative to the maximum operating speed, and reduction in electricity cost relative to the maximum operating speed.

[0095] In the simulation program of this embodiment, step S2 calculates the amount of work done by each of the press devices 1P to 5P and the feeder devices LD, 1F, 2F, 3F, 4F, and UL in the motion of the press line 1. In steps S3 and S4, the power consumption of the press line 1 is calculated based on the calculated amount of work done by each device.

[0096] In this way, by calculating the workload of each of the press devices 1P to 5P and the feeder devices LD, 1F, 2F, 3F, 4F, and UL, it is possible to calculate information regarding the power consumption of press line 1.

[0097] In the simulation program of this embodiment, step S2 calculates the amount of work done by each of the press devices 1P to 5P in the motion of the press line 1. Steps S3 and S4 calculate the power consumption of the press line 1 based on the calculated amount of work done by each device.

[0098] In this way, by calculating the workload of each press device 1P to 5P, it is possible to calculate information regarding the power consumption of press line 1. Since the press devices consume more power than the conveying devices, the approximate power consumption of press line 1 can be determined by calculating the power consumption of the press devices alone.

[0099] In the simulation program of this embodiment, in steps S3 and S4, the calculated workload of each device is added together to calculate the workload of press line 1, and information regarding the power consumption per workpiece W is calculated.

[0100] This allows the worker to check the power consumption when manufacturing one workpiece W. If the unit price of electricity is known, the production cost per workpiece W may be displayed instead of, or in addition to, the power consumption. The production cost corresponds to an example of information regarding power consumption.

[0101] In the simulation program of this embodiment, in step S2, the amount of work done by the servo motor 21 is calculated from the motion of the slide 14 of the press devices 1P to 5P in the motion of the press line 1, and the amount of work done by the servo motor (not shown) that moves the first motor 46, the second motor 47 and the first drive device 31 in the transport direction X, and the servo motor (not shown) that moves the first motor 46', the second motor 47' and the second drive device 32 in the transport direction X is calculated from the motion of the feeder devices LD, 1F, 2F, 3F, 4F, and UL in the motion of the press line 1, and the amount of work done by the servo motor (not shown) that moves the first motor 46', the second motor 47' and the second drive device 32 in the transport direction X is calculated, and the amount of work done by the press line 1 is calculated.

[0102] This allows for the calculation of the workload of the press and feeder devices.

[0103] In the simulation program of this embodiment, press devices 1P to 5P each have a servo motor 21 that moves the slide 14 up and down. In step S2, the amount of work done by the servo motor 21 is calculated from the motion of the slide 14 of press devices 1P to 5P in the motion of the press line 1, and the amount of work done by press devices 1P to 5P is calculated.

[0104] This allows us to calculate the workload of the press machine.

[0105] In the simulation program of this embodiment, in press line 1, a phase difference is provided between the motion of slide 14 of press device 1P and the motion of slide of press device 2P, where the positions of the slides at a predetermined time are different.

[0106] This makes it possible to calculate the power consumption of a press line in a press line where a phase difference is introduced between at least two of the multiple press devices 1P to 5P during the lifting and lowering drive.

[0107] In the simulation program of this embodiment, press devices 1P to 5P are connected to the same factory power supply.

[0108] This allows us to check the power consumption supplied from the same factory power source. Furthermore, the power regenerated by any of the press devices 1P to 5P can be used for other devices operating at the same time. Therefore, power consumption in press line 1, including press devices 1P to 5P, can be reduced.

[0109] The recording medium of this embodiment is a recording medium on which a simulation program is recorded, and which is processable by a computer.

[0110] The simulation method of this embodiment is a simulation method for simulating the motion of a press line equipped with press devices 1P to 5P for press processing a workpiece W, and comprises steps S1 (an example of a motion generation step) and steps S2 to S4 (an example of power consumption information calculation steps). In step S1, the motion of press line 1 is generated. In steps S2 to S4, information regarding the power consumption of press line 1 is calculated based on the motion of press line 1.

[0111] Therefore, it is possible to generate press line motion with reduced power consumption.

[0112] The simulation device 5 of this embodiment is a simulation device for simulating the motion of a press line equipped with press devices 1P to 5P for press processing a workpiece W, and comprises a motion generation unit 51a and a power consumption calculation unit 51b. The motion generation unit 51a generates the motion of the press line 1. The power consumption calculation unit 51b calculates information regarding the power consumption of the press line 1 based on the motion of the press line 1.

[0113] Therefore, it is possible to generate press line motion with reduced power consumption.

[0114] <4. Other Embodiments> Although one embodiment of the present invention has been described above, the present invention is not limited to the above embodiment, and various modifications are possible without departing from the spirit of the invention.

[0115] (A) In the above embodiment, the press line control device 4 and the simulation device 5 are connected by wire or wireless means, but they do not necessarily have to be connected. For example, the press line motion program generated by the simulation device 5 may be recorded on a recording medium such as an SD card, and the press line control device 4 may acquire the press line motion program by reading the recording medium.

[0116] (B) In the above embodiment, the power consumption of the press line 1 is displayed in the display portion 70a of the display unit 53, but it is not limited to the power consumption itself; it is sufficient to display information related to power consumption. Examples of information related to power consumption include CO2 emissions, electricity costs, production costs, reductions from power consumption at maximum operating speed, reductions from CO2 emissions at maximum operating speed, reductions from electricity costs at maximum operating speed, or reductions from production costs at maximum operating speed.

[0117] (C) The press line 1 in the above embodiment includes six feeder devices LD, 1F, 2F, 3F, 4F, and UL, and five press devices 1P to 5P, but is not limited to this configuration.

[0118] (D) In the above embodiment, the simulation device 5 is located separately from the press line 1, but it may be incorporated into the press line 1.

[0119] (E) In the above embodiment, the power consumption per product is displayed, but it may be communicated to the worker by voice or other means instead of being displayed.

[0120] (G) In the above embodiment, a phase difference is provided in the multiple press devices 2, but a phase difference is not required.

[0121] (H) Furthermore, the recording medium of this disclosure is a recording medium that records a program in which a computer executes all or part of the steps of the simulation method of this disclosure described above, and is a recording medium that is readable by a computer and in which the read program cooperates with the computer to execute the said operations. One form of use of the program of the present invention may be recorded on a storage medium such as ROM that is readable by a computer and operate in cooperation with the computer. Another form of use of the program of the present invention may be transmitted through a transmission medium such as the internet, or a transmission medium such as light or radio waves, read by a computer, and operate in cooperation with the computer. Furthermore, the computer of the present invention described above is not limited to pure hardware such as a CPU, but may also include firmware, an OS, and peripheral devices. Furthermore, the configuration of the present invention may be implemented in software or in hardware. [Industrial applicability]

[0122] The simulation program disclosed herein can provide a simulation program, recording medium, simulation method, and simulation apparatus that can verify information that serves as an indicator of energy consumption. [Explanation of Symbols]

[0123] 1: Press line 2: Pressing device 1P~5P: Pressing device 3: Feeder device LD, 1F, 2F, 3F, 4F, UL: Feeder equipment 4: Press line control device 5: Simulation device 51: Simulation Department 51a: Motion generation unit 51b: Power consumption calculation section 51c: Display Control Unit 51d: 1st calculation section 51e: 2nd calculation section 52: Input section 53:Display section 54: Communications Department

Claims

1. A simulation program for simulating the motion of a press line equipped with a first press device for processing a workpiece, A motion generation step for generating the motion of the press line, The computer is made to perform a power consumption information calculation step, which calculates information regarding the power consumption of the press line based on the motion of the press line. The press line further comprises a first conveying device for loading or unloading the workpiece into or from the first press device. The power consumption information calculation step is: A first calculation step of calculating the amount of work done by the first press device and the first conveying device in the motion of the press line, The process includes a second calculation step of calculating information regarding the power consumption of the press line based on the calculated amount of work, Simulation program.

2. A simulation program for simulating the motion of a press line equipped with a first press device for processing a workpiece, A motion generation step for generating the motion of the press line, The computer is made to perform a power consumption information calculation step, which calculates information regarding the power consumption of the press line based on the motion of the press line. The press line further comprises a second press device for press-forming the workpiece, The power consumption information calculation step is: A first calculation step of calculating the amount of work done by the first press device and the second press device in the motion of the press line, The process includes a second calculation step of calculating information regarding the power consumption of the press line based on the calculated amount of work, Simulation program.

3. The simulation program according to claim 1 or 2, further comprising a display step in which the computer performs a display step of displaying information regarding the calculated power consumption of the press line.

4. In the second calculation step, the amount of work done by each of the work amounts is added together to calculate the amount of work done by the press line, and information regarding the power consumption per workpiece is calculated. The simulation program according to claim 1 or 2.

5. The first press device has a servo motor that moves the slide up and down, The first transport device has a servo motor as a drive source, In the first calculation step, the amount of work done by the servo motor is calculated from the motion of the slide of the first press device in the motion of the press line, and the amount of work done by the servo motor is calculated from the motion of the first conveying device in the motion of the press line, and the amount of work done by the first conveying device is calculated. The simulation program according to claim 1.

6. Each of the first press device and the second press device has a servo motor that moves the slide up and down. In the first calculation step, the amount of work done by the servo motor is calculated from the motion of the slide of the first press device in the motion of the press line, and the amount of work done by the servo motor is calculated from the motion of the slide of the second press device in the motion of the press line, and the amount of work done by the second press device is calculated. The simulation program according to claim 2.

7. In the motion of the press line, a phase difference is provided between the motion of the slide of the first press device and the motion of the slide of the second press device, where the positions of the slides at a predetermined time are different. The simulation program according to claim 2.

8. The first press device and the second press device are connected to the same factory power supply. The simulation program according to claim 2.

9. A recording medium that stores the simulation program described in claim 1 or 2, and is processable by a computer.

10. A simulation method for simulating the motion of a press line comprising a first press device for processing a workpiece and a first conveying device for loading or unloading the workpiece into or from the first press device, A motion generation step for generating the motion of the press line, The system includes a power consumption information calculation step that calculates information regarding the power consumption of the press line based on the motion of the press line, The power consumption information calculation step is: A first calculation step of calculating the amount of work done by the first press device and the first conveying device in the motion of the press line, The process includes a second calculation step of calculating information regarding the power consumption of the press line based on the calculated amount of work, Simulation method.

11. A simulation method for simulating the motion of a press line comprising a first press device for processing a workpiece and a second press device for press-forming the workpiece, A motion generation step for generating the motion of the press line, The system includes a power consumption information calculation step that calculates information regarding the power consumption of the press line based on the motion of the press line, The power consumption information calculation step is: A first calculation step of calculating the amount of work done by the first press device and the second press device in the motion of the press line, The process includes a second calculation step of calculating information regarding the power consumption of the press line based on the calculated amount of work, Simulation method.

12. A simulation device for simulating the motion of a press line comprising a first press device for processing a workpiece and a first conveying device for loading or unloading the workpiece into or from the first press device, A motion generation unit that generates the motion of the press line, The system includes a power consumption information calculation unit that calculates information regarding the power consumption of the press line based on the motion of the press line, The power consumption information calculation unit is, A first calculation unit that calculates the amount of work done by the first press device and the first conveying device in the motion of the press line, It includes a second calculation unit that calculates information regarding the power consumption of the press line based on the calculated amount of work, Simulation device.

13. A simulation device for simulating the motion of a press line comprising a first press device for processing a workpiece and a second press device for press-forming the workpiece, A motion generation unit that generates the motion of the press line, The system includes a power consumption information calculation unit that calculates information regarding the power consumption of the press line based on the motion of the press line, The power consumption information calculation unit is, A first calculation unit that calculates the amount of work done by the first press device and the second press device in the motion of the press line, It includes a second calculation unit that calculates information regarding the power consumption of the press line based on the calculated amount of work, Simulation device.

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