Method for detecting and avoiding dangerous situations for an operator when machining a workpiece

Abstract

The invention relates to a method for detecting dangerous situations for an operator when machining a workpiece (1) by means of a bending press process using a bending machine (9), having the steps of detecting a dangerous point in the working region (5) of the bending machine (9) and initiating a measure for avoiding or controlledly handling the dangerous point, the step of initiating a measure involving an intervention in the bending press procedure of the bending press process and / or a modification of the bending press procedure in order to control the bending press process of the bending machine (9).

Description

[0001] METHOD FOR DETECTING AND AVOIDING HAZARDOUS SITUATIONS FOR AN OPERATOR WHILE PROCESSING A WORKPIECE

[0002] The invention relates to methods for detecting hazardous situations for an operator during the processing of a workpiece by means of a bending press or press brake operation using a bending machine or a press brake. For improved readability, the invention is explained below for a bending machine, whereby the invention is equally applicable to a press brake or a similar forming device.

[0003] From EP 3 507 034 Bl a bending machine is known which bending machine has a working plane that defines a front working and manipulation area and a rear machine room separated from it, and in particular enclosed, wherein a projector is arranged in the rear machine room and above an insertion plane, which has a beam path directed away from the insertion plane, in particular an upward beam path, and wherein a reflector with a first reflecting surface is arranged in the working and manipulation area, which first reflecting surface is arranged pivoted at an angle to the horizontal, such that a light beam incident from the beam path of the projector leaves the first reflecting surface as an outgoing light beam of a beam path of the reflector in the direction of the insertion plane.The document further reveals that bending information is generated by at least one of the following groups: workpiece contour, bending line, control panel, press beam status data, alignment information, target angle, piece counter, and areas on the sheet metal to be formed with an increased risk of injury during the bending process. In particular, all bending program data can be visualized. The workpiece contour ensures that the operator is clearly and unambiguously shown how a workpiece must be inserted into the press brake for the next processing step. During handling operations, the operator must grasp the sheet metal, and this advanced design makes it possible to visualize those areas on the workpiece where there is a risk of injury from the forming sheet metal during the bending process.

[0004] The object of the present invention was to further develop and improve the detection of hazardous situations known from the prior art and to provide a method and a bending machine by means of which the safe operation of a bending machine is improved. This object is achieved by the measures according to the claims.

[0005] The invention relates to a method for detecting and avoiding hazardous situations for an operator during the processing of a workpiece by means of a bending press operation using a bending machine, specifying a bending press procedure, the bending machine comprising a lower tool and an upper tool, wherein the upper tool is movable relative to the lower tool within a working area and can be brought close to the lower tool in order to be able to process a workpiece that can be positioned between the upper tool and the lower tool within the working area, the method comprising the following process steps:

[0006] - Detecting a hazard point in the working area of ​​the bending machine by detecting a distance between machine components of the bending machine and the workpiece, in particular between machine components of the bending machine and a section of the workpiece, specifically an end section of the workpiece;

[0007] - Initiating measures to avoid or specifically manage the hazard;

[0008] - wherein the detection of hazards and the initiation of measures are carried out during a bending press operation of the bending machine, wherein the bending press operation is simulated in a simulation of the bending press operation, in particular in a simulation with a virtual twin of the bending machine and the workpiece, at least approximately in time parallel to the bending press operation of the bending machine, and

[0009] - where the initiation of measures includes intervention in the press bending process and / or modification of the press bending process to control the press bending process of the bending machine.

[0010] In the context of the invention, a virtual twin can be understood, for example, as a dynamic geometric 3D model of the bending machine and the workpiece.

[0011] According to the invention, the bending process is simulated, specifically in close temporal proximity to the actual bending process performed on the bending machine. Hazardous areas are identified so that appropriate measures can be initiated based on their detection or recognition. Naturally, this method is equally applicable to a press brake or a workpiece processing machine similar to a bending machine. In any case, this allows for a very simple yet effective way to improve the safety of the bending machine operator.

[0012] Furthermore, it may be useful to define the danger point as an approach of the workpiece section, in particular the end section of the workpiece, to machine components, especially the upper tool or the lower tool, initiated by deformation and / or by unloading of a workpiece during the bending press process.

[0013] Furthermore, it may be provided that, as a measure, the bending press process of the bending machine is interrupted or stopped and / or that an audible or visual warning signal is issued at the bending machine.

[0014] Furthermore, it may be provided that the interrupted bending press process is continued by acknowledging the warning signal.

[0015] It is also advantageous to have a configuration in which the interrupted bending process can be continued by direct and continuous release of the further bending process by an operator of the bending machine.

[0016] The invention also relates to a bending machine comprising means adapted to perform the steps of the method according to the preceding description.

[0017] Furthermore, the invention includes a computer program product comprising commands that cause the aforementioned bending machine to perform the process steps according to the preceding description.

[0018] The invention also relates to a computer-implemented method for detecting and avoiding hazardous situations for an operator during the processing of a workpiece by means of a bending press operation using a bending machine, the bending machine comprising a lower tool and an upper tool, wherein the upper tool is movable relative to the lower tool within a working area and can be brought close to the lower tool in order to be able to process a workpiece that can be positioned between the upper tool and the lower tool within the working area, the method comprising the following process steps:

[0019] - Providing virtual component parts of the bending machine, in particular a virtual twin of the bending machine, and a virtual twin of the workpiece with defined positioning of the workpiece relative to the virtual bending machine;

[0020] - Simulating a virtual press brake process;

[0021] - Detecting a hazard point in the working area of ​​the bending machine by detecting a distance between machine components of the bending machine and the workpiece, in particular between machine components of the bending machine and a section of the workpiece, especially an end section of the workpiece, during the simulation of the virtual bending press process;

[0022] - Initiating measures to avoid or specifically manage the hazard;

[0023] - Deriving and storing a bending press process, improved in particular by the preceding process steps, for carrying out the bending press operation using the bending machine based on the virtual bending press operation.

[0024] According to further training, it is possible that the danger point is defined as an approach of the end section of the workpiece to machine components, in particular to the upper tool or the lower tool, initiated by deformation and / or by relief of a workpiece during the bending press process.

[0025] Furthermore, it may be useful to define a new positioning of the virtual workpiece relative to the virtual bending machine for the virtual bending press process, whereby the virtual bending process is simulated again.

[0026] Furthermore, it may be possible to implement a measure to stop the bending press process of the bending machine in the bending press procedure.

[0027] Furthermore, the invention includes a computer program product comprising commands which, when the program is executed by a computer, cause it to execute the method according to the preceding description.

[0028] The invention also relates to a bending machine comprising a data processing device, wherein the data processing device includes means for carrying out the method according to the preceding description. The invention further relates to a method for detecting hazardous situations for an operator during the processing of a workpiece by means of a bending press operation using a bending machine, the bending machine comprising a lower tool and an upper tool, wherein the upper tool is movable relative to the lower tool within a working area and can be brought close to the lower tool in order to be able to process a workpiece that can be positioned between the upper tool and the lower tool within the working area, the method comprising the following process steps:

[0029] - Detection of the work area by means of a visual monitoring device, wherein the visual monitoring device is in communication link with a control device of the bending machine;

[0030] - Continuous visual monitoring of the work area using the visual monitoring device during a bending press operation;

[0031] - wherein an approach of an end section of the workpiece to the upper tool or to the lower tool, initiated by deformation and / or by unloading of a workpiece during the bending press process, is detected by the visual monitoring device.

[0032] Naturally, this method is equally applicable to a press brake or a workpiece processing machine similar to a bending machine. In any case, it offers a very simple yet effective way to improve the safety of the bending machine operator.

[0033] Furthermore, it can be advantageous for the visual monitoring device to detect the distance between the end section and the upper or lower tool during the press brake process, and for the control device to initiate safety measures if the distance falls below a certain limit. This further increases safety, as hazardous situations can be defused or even reversed immediately.

[0034] Furthermore, it may be stipulated that, as a safety measure, the bending press process is interrupted or stopped and / or that an audible or visual warning signal is issued. Such signaling further increases safety.

[0035] Furthermore, it can be provided that the interrupted bending press operation is resumed by acknowledging the warning signal. This allows a bending press operation to be easily restarted while maintaining improved operator safety.

[0036] Another advantageous feature is a design that allows for the interrupted bending process to be resumed by a direct and continuous release of the bending process by an operator of the bending machine. This enables a so-called hold-to-run sequence of the bending process to be initiated, thus maintaining operator safety during the further course of the bending process, as the hazardous situation may persist or even worsen.

[0037] According to further training, it is possible to detect and visually monitor the work area using a sensor, in particular an ultrasonic sensor, an infrared sensor and / or a 3D camera as a visual monitoring device. This method can thus be implemented using simple means.

[0038] The invention also relates to a bending machine comprising an upper tool, a lower tool and a control device in communication connection with a visual monitoring device, wherein the control device and the visual monitoring device are adapted so that the method according to one of the preceding claims can be carried out using the bending machine.

[0039] Furthermore, the invention relates to a computer program product comprising the commands that cause a bending machine of the aforementioned type to perform the process steps according to the preceding description.

[0040] The invention also relates to a method for adapting the computer program product of the aforementioned type for a specific workpiece geometry, comprising the following method steps:

[0041] - Determining a plunge depth of the upper tool in the direction of the lower tool during a first workpiece orientation, at which plunge depth the end section of the workpiece falls below a limit value for a distance to the upper tool or to the lower tool;

[0042] - Integrating or modifying safety measures for the press brake process at a specific immersion depth. A specific workpiece geometry refers to the geometry of a workpiece, which may differ from another workpiece with a different geometry. In any case, the computer program can be easily adapted to any workpiece geometry using this adaptation method, ensuring the continued applicability of the hazard prevention procedure.

[0043] Furthermore, it may be expedient to specify a second workpiece orientation as a safety measure, which differs from the first workpiece orientation, whereby in the second workpiece orientation, any falling below the limit value for the distance is shifted to an inner area of ​​the bending machine, away from an operator of the bending machine and shielded by the upper tool and lower tool.

[0044] To better understand the invention, it is explained in more detail with reference to the following figure.

[0045] It shows, in a highly simplified, schematic representation:

[0046] Fig. 1 shows a bending press operation of a workpiece using the method according to the invention;

[0047] It should be noted at the outset that in the differently described embodiments, identical parts are provided with the same reference numerals or component designations, and the disclosures contained in the entire description can be applied analogously to identical parts with the same reference numerals or component designations. Furthermore, the positional designations chosen in the description, such as top, bottom, side, etc., refer to the figure directly described and illustrated, and these positional designations must be applied analogously to the new position if the position changes.

[0048] Figure 1 shows a possible embodiment or variant of the press bending process of a workpiece 1 using a method as described above, in a highly simplified, schematic representation. The method can be applied using a bending machine, wherein the bending machine comprises at least an upper tool 2, a lower tool 3, and a control device in communication with a visual monitoring device 4. The control device is configured to move at least the upper tool 2 in the direction of the lower tool 3, according to a setting in a bending program, so that a workpiece 1, which is positioned between the upper tool 2 and the lower tool 3, can be formed by a press bending process.

[0049] The method is designed to detect hazardous situations for an operator during the processing of a workpiece 1 by means of a press bending operation using the bending machine. The method comprises detecting a hazard point in a work area 5 or, alternatively, detecting a work area 5 using a visual monitoring device 4 and continuously monitoring the work area 5 visually using the visual monitoring device 4 during a press bending operation for processing a workpiece 1.

[0050] In particular, the method is characterized in that the danger zone in the working area 5 of the bending machine 9 is detected by measuring a distance 7 between machine components of the bending machine 9 and the workpiece 1, in particular between machine components of the bending machine 9 and a section of the workpiece 1, specifically an end section 6 of the workpiece 1.

[0051] Based on this, measures to avoid or to specifically manage the hazard can be initiated, wherein the detection of hazards and the initiation of measures are carried out during a bending press operation of the bending machine 9, wherein the bending press operation is simulated in a simulation of the bending press operation, in particular in a simulation with a virtual twin of the bending machine 9 and the workpiece 1, at least approximately in parallel with the bending press operation of the bending machine 9, and wherein the initiation of measures includes intervention in the bending press operation and / or modification of the bending press operation to control the bending press operation of the bending machine 9.

[0052] Alternatively, it is also conceivably advantageous that the method can be carried out as a purely computer-implemented method, whereby virtual component components of the bending machine 9, in particular a virtual twin of the bending machine 9, and a virtual twin of the workpiece 1, specifically a dynamic, geometric 3D model of the bending machine and the workpiece 1, with defined positioning of the workpiece 1 relative to the virtual bending machine 9, are provided.Furthermore, a virtual press bending process is simulated, whereby a hazard point in the working area 5 of the bending machine 9 is detected by measuring a distance 7 between machine components of the bending machine 9 and the workpiece 1, in particular between machine components of the bending machine 9 and a section of the workpiece 1, especially an end section 6 of the workpiece 1, during the simulation of the virtual press bending process, in order to ultimately initiate a measure or measures to avoid or specifically manage the hazard point. This subsequently enables the derivation and storage of a press bending process, improved in particular by the preceding process steps, for carrying out the press bending process using the bending machine 9 based on the virtual press bending process.

[0053] In an alternative embodiment, the method can be characterized in that an approach of an end section 6 of the workpiece 1 to the upper tool 2 or to the lower tool 3, initiated by deformation and / or by unloading of a workpiece 1 during the bending press process, is detected by the visual monitoring device 4.

[0054] In particular, it can be provided that the visual monitoring device 4 detects a distance 7 of the end section 6 to the upper tool 2 or to the lower tool 3 during the bending press process, whereby if a limit value for the distance 7 is undershot, safety measures are initiated by the control device.

[0055] As a safety measure, it may be implemented, for example, that the bending process is interrupted or stopped and / or that an audible or visual warning signal is issued. As an advantageous further measure, it may be implemented that the interrupted bending process is resumed by acknowledging the warning signal. Alternatively, it may also be implemented that the interrupted bending process is resumed by a direct and continuous release of the bending process by an operator of the bending machine.

[0056] In any case, the detection and visual monitoring of the working area 5 can be carried out using an ultrasonic sensor, an infrared sensor and / or a 3D camera as a visual monitoring device (4). The invention also relates to a computer program product comprising the commands that cause a bending machine of the type described above to perform the process steps described above.

[0057] Furthermore, a method for adapting the computer program product is also provided, so that the computer program product can be adapted for a specific workpiece geometry. This method includes at least determining the immersion depth of the upper tool 2 in the direction of the lower tool 3 for a first workpiece orientation, at which immersion depth the end section 6 of the workpiece 1 falls below a limit value for a distance 7 to the upper tool 2 or to the lower tool 3, and introducing or modifying safety measures for the press brake operation at the determined immersion depth, whereby the safety measures are understood to be, for example, the aforementioned safety measures.In this context, a second workpiece orientation, different from the first, can be specified as a safety measure. In this second workpiece orientation, any deviation below the limit value for the distance 7 is shifted to an interior area 8 of the bending machine, facing away from the operator and shielded by the upper tool 2 and lower tool 3. This second workpiece orientation is illustrated, for example, in Fig. 1.

[0058] The exemplary embodiments show possible embodiment variants, whereby it should be noted at this point that the invention is not limited to the specifically illustrated embodiment variants, but rather various combinations of the individual embodiment variants are also possible and this possibility of variation lies within the skill of the person skilled in this technical field due to the teaching on technical action by the present invention.

[0059] The scope of protection is defined by the claims. However, the description and drawings must be consulted for the interpretation of the claims. Individual features or combinations of features from the different embodiments shown and described can, in themselves, represent independent inventive solutions. The problem underlying these independent inventive solutions can be found in the description. All references to value ranges in this description are to be understood as encompassing any and all sub-ranges thereof. For example, the reference 1 to 10 is to be understood as including all sub-ranges, starting from the lower limit 1 and the upper limit 10. That is, all sub-ranges begin with a lower limit of 1 or greater and end with an upper limit of 10 or less, e.g., 1 to 1.7, or 3.2 to 8.1, or 5.5 to 10.

[0060] Finally, for the sake of clarity, it should be noted that, for a better understanding of the structure, some elements have been shown not to scale and / or enlarged and / or reduced in size.

[0061] Reference numeral list Workpiece Upper tool Lower tool Monitoring device Working area End section Distance Inner area Bending machine

Claims

Patent claims 1. Method for detecting and avoiding hazardous situations for an operator when processing a workpiece (1) by means of a bending press operation using a bending machine (9) according to a specified bending press procedure, the bending machine (9) comprising a lower tool (3) and an upper tool (2), wherein the upper tool (2) is movable relative to the lower tool (3) within a working area (5) and can be brought towards the lower tool (3) in order to be able to process a workpiece (1) that can be positioned between the upper tool (2) and the lower tool (3) within the working area (5), the method comprising the following process steps: - Detecting a hazard in the working area (5) of the bending machine (9) by detecting a distance (7) between machine components of the bending machine (9) and the workpiece (1), in particular between machine components of the bending machine (9) and a section of the workpiece (1), specifically an end section (6) of the workpiece (1); - Initiating a measure to avoid or specifically manage the hazard; characterized by, - that the detection of hazards and the initiation of measures are carried out during a bending press operation of the bending machine (9), wherein the bending press operation is simulated in a simulation of the bending press operation, in particular in a simulation with a virtual twin of the bending machine (9) and the workpiece (1), at least approximately in time parallel to the bending press operation of the bending machine (9), and - that the initiation of measures includes intervention in the press bending process and / or modification of the press bending process to control the press bending process of the bending machine (9).

2. Method according to claim 1, characterized in that the danger point is defined as an approach of the section of the workpiece (1), in particular the end section (6) of the workpiece (1), to machine components, in particular to the upper tool (2) or to the lower tool (3), initiated by deformation and / or by relief of a workpiece (1) during the bending press process.

3. Method according to one of claims 1 or 2, characterized in that, as a measure, the bending press process of the bending machine (9) is interrupted or stopped and / or an audible or visual warning signal is issued at the bending machine (9).

4. Method according to claim 3, characterized in that the interrupted bending press process is continued by acknowledging the warning signal.

5. Method according to claim 3, characterized in that the interrupted bending press process is continued by direct and continuous release of the further bending press process by an operator of the bending machine (9).

6. Bending machine (9) comprising means adapted to perform the steps of the method according to any of the preceding claims.

7. Computer program product comprising instructions that cause the device of claim 6 to perform the method steps according to any one of claims 1 to 5.

8. Computer-implemented method for detecting and avoiding hazardous situations for an operator when processing a workpiece (1) by means of a press bending operation using a bending machine (9) under a specified press bending procedure, the bending machine (9) comprising a lower tool (3) and an upper tool (2), wherein the upper tool (2) is movable relative to the lower tool (3) within a working area (5) and can be brought towards the lower tool (3) in order to be able to process a workpiece (1) that can be positioned between the upper tool (2) and the lower tool (3) within the working area (5), the method comprising the following process steps: - Providing virtual component parts of the bending machine (9), in particular a virtual twin of the bending machine (9), and a virtual twin of the workpiece (1) with defined positioning of the workpiece (1) relative to the virtual bending machine (9); - Simulating a virtual press brake process; - Detecting a hazard in the working area (5) of the bending machine (9) by detecting a distance (7) between machine components of the bending machine (9) and the - 15 - Workpiece (1), in particular between machine components of the bending machine (9) and a section of the workpiece (1), in particular an end section (6) of the workpiece (1), during the simulation of the virtual bending press process; - Initiating measures to avoid or specifically manage the hazard; - Deriving and storing a bending press method, improved in particular by the preceding process steps, for carrying out the bending press operation using the bending machine (9) on the basis of the virtual bending press operation.

9. Computer-implemented method according to claim 8, characterized in that the danger point is detected as an approach of the end section (6) of the workpiece (1) to machine components, in particular to the upper tool (2) or to the lower tool (3), initiated by deformation and / or by unloading of a workpiece (1) during the bending press process.

10. Computer-implemented method according to one of claims 8 or 9, characterized in that, as a measure, a new positioning of the virtual workpiece (1) relative to the virtual bending machine (9) is defined for the virtual bending press operation, wherein the virtual bending operation is simulated again.

11. Computer-implemented method according to one of claims 8 or 9, characterized in that a stop of the bending press process of the bending machine (9) is implemented as a measure in the bending press process.

12. Computer program product comprising instructions which, when the program is executed by a computer, cause it to execute the method according to any one of claims 8 to 11.

13. Bending machine (9) comprising a data processing device, wherein the data processing device comprises means for carrying out the method according to one of claims 8 to 11. - 16 - 14. Method for detecting hazardous situations for an operator during the processing of a workpiece (1) by means of a press bending operation using a bending machine (9) under a specified press bending procedure, the bending machine (9) comprising a lower tool (3) and an upper tool (2), wherein the upper tool (2) is movable relative to the lower tool (3) within a working area (5) and can be brought towards the lower tool (3) in order to be able to process a workpiece (1) that can be positioned between the upper tool (2) and the lower tool (3) within the working area (5), the method comprising the following process steps: - Detection of the work area (5) by means of a visual monitoring device (4), wherein the visual monitoring device (4) is in communication link with a control device of the bending machine (9); - Continuous visual monitoring of the work area (5) by means of the visual monitoring device (4) during the bending press process; characterized in that, - that an approach of a section of the workpiece (1), in particular an end section (6) of the workpiece (1), to machine components of the bending machine (9), in particular to the upper tool (2) or to the lower tool (3), initiated by deformation and / or by unloading of a workpiece (1) during the bending press process, is detected by the visual monitoring device (4).

15. Method according to claim 14, characterized in that the visual monitoring device (4) detects a distance (7) of the section of the workpiece (1), in particular the end section (6), to machine components of the bending machine (9), in particular to the upper tool (2) or to the lower tool (3) during the bending press process, wherein safety measures are initiated when a limit value for the distance (7) is undershot by the control device.

16. Method according to claim 15, characterized in that, as a safety measure, the bending press process is interrupted or stopped and / or an audible or visual warning signal is issued. - 17 - 17. Method according to claim 16, characterized in that the interrupted bending press process is continued by acknowledging the warning signal.

18. Method according to claim 16, characterized in that the interrupted bending press process is continued by direct and continuous release of the further bending press process by an operator of the bending machine (9).

19. Method according to one of claims 14 to 18, characterized in that the detection and visual monitoring of the work area (5) is carried out by means of a sensor, in particular by means of an ultrasonic sensor, an infrared sensor and / or a camera, in particular a 3D camera as a visual monitoring device (4).

20. Bending machine (9) comprising means adapted to perform the steps of the method according to any one of claims 14 to 19.

21. Computer program product comprising the commands that cause a bending machine (9) according to claim 20 to perform the process steps according to any one of claims 14 to 19.

22. Method for adapting the computer program product according to claim 21 for a specific workpiece geometry of a workpiece (1), comprising the following method steps: - Determining an immersion depth of the upper tool (2) in the direction of the lower tool (3) during a first workpiece orientation, at which immersion depth a section of the workpiece (1), in particular the end section (6) of the workpiece (1), falls below a limit value for a distance (7) to machine components of the bending machine (9), in particular to the upper tool (2) or to the lower tool (3); - Integrating or adapting safety measures for the bending press process at the specified immersion depth.

23. Method according to claim 22, characterized in that, as a safety measure, a second workpiece orientation, different from the first workpiece orientation, is used. - 18 - is specified, whereby in the second workpiece orientation, a fall below the limit value for the distance (7) is shifted into an inner area (8) of the bending machine (9) which is away from an operator of the bending machine (9) and is shielded by upper tool (2) and lower tool (3).

Images