Method for displaying handling assistance image and device for controlling press brake

Abstract

Upon detecting that bend-machining of a workpiece (W) in a press brake (10) has started, an NC device (10) displays, on a display device (30), a handling image that indicates the manner in which the workpiece (W) is to be held by an operator of the press brake (100). Upon detecting that the workpiece (W) has been inserted into the press brake (100), the NC device (10) displays, on the display device (30), a workpiece image that indicates the workpiece (W) pressed against an abutment (42), the workpiece image being displayed so as to be superimposed on a captured image obtained by imaging the abutment (42) and the workpiece (W). Upon detecting that the workpiece (W) has been removed from the press brake (100), the NC device (10) displays, on the display device (30), a change assistance image that indicates a procedure for changing from the manner in which the workpiece (W) is held in the current step to the manner in which the workpiece (W) is to be held in the next step.

Description

Handling support image display method and press brake control device

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

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

[0003] Special Publication No. 2021-534975

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

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

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

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

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

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

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

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

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

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

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

[0015] In addition, when performing bending processing using the press brake 100, the NC device 10 performs control to display images to assist the operator of the press brake 100 in handling the workpiece W.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

[0055] The disclosure of this application is related to the subject matter described in Japanese Patent Application No. 2024-153698, filed on September 6, 2024, the entire disclosure of which is incorporated herein by reference.

Claims

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

2. A method for displaying a handling support image as described in claim 1, wherein the handling image shows the workpiece oriented in the direction of insertion into the press brake and the position in which the worker holds the workpiece.

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

4. A method for displaying a handling support image as described in claim 1, wherein the change support image displays an animation of the change in the workpiece from the way it is held in the current process to the way it is held in the next process, along with an arrow indicating the direction in which the workpiece should be rotated.

5. A press brake control device that, when it detects that bending of a workpiece has begun with a press brake, displays on the display device of the press brake a handling image showing how the workpiece is being held by the operator of the press brake; when it detects that the workpiece has been inserted into the press brake, displays on the display device a workpiece image showing the workpiece pressed against the stop of the press brake, superimposed on an image of the stop and the workpiece; and, when it detects that the workpiece has been removed from the press brake, displays on the display device a change support image showing the procedure for changing from the way the workpiece is being held in the current process to the way the workpiece is being held in the next process.

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