Method and machine system for controlling an industrial operation

专利摘要:
The present invention relates to a method for selecting optimum operation performance criteria for a metal working process. The method comprises the step of developing a process model relating process parameters for the operation with performance variables for said operation, wherein the process parameters and performance variables are retrievable via integrated multiple data sources, and selecting at least one optimization technique to define a function, said function comprising of process parameters. Moreover, generating the function for optimization by using acceptable tolerances of a product to be machined as a basis to define ranges for performance variables along with ranges for process parameters, and applying the at least one optimization technique to said function, whereby optimum operation performance criteria are calculated for the process model including process parameters and performance variables to obtain a set of requirements to be used for controlling the metal working process.(Figure 1 for publication)
公开号:SE1651338A1
申请号:SE1651338
申请日:2016-10-12
公开日:2017-08-20
发明作者:Norberg Olsson Magnus
申请人:Tomologic Ab；
IPC主号:

专利说明:

1 Method and machine system for controlling an industrial operation TECHNICAL FIELD The present invention relates to a method, an industrial machine system, a computer programproduct and a non-transient computer-readable medium for selecting optimum operationperformance criteria for controlling an industrial machining operation, such as a sheet metal working process.
BACKGROUND ART Industrial machine systems of today typically consist of a machine with an actuator system forproviding relative motion between a machine part or operating device and a workpiece. Stateof the art industrial machine systems are highly specialised to perform operations like forinstance beam cutting, milling, turning, drilling, boring, punching, punch pressing, press-breaking, bending, welding and assembly operations. The machine system is a substantialinvestment to most potential customers, in particular to smaller or medium-sized workshops,why the versatility and productivity that the machine system is to contribute with to the business is a key factor when making investment decisions.
The industrial machine systems are controlled by means of a CNC (Computerized NumericalControl) unit, an NC (Numerical Control) unit, a PLC (Programmable Logical Control) unitand/or related sensing and processing equipment that together serve to provide instructionsto an actuator system to perform required movements in order to execute intended industrialoperations. The machine system further comprises a machine controller, which is essentially acomputer having a processor and a conventional operating system such as Windows or Linuxconfigured to give instructions to the CNC/NC/PLC unit based on machine controllerinstructions, such as G-code or XI/|L. The machine controller includes or is connected to anHMI (Human-Machine Interface), and is configured to read programs and to gather processparameters so as to yield complete instructions to the CNC/NC/PLC unit for execution by the actuator system comprised in the machine. Conventionally, both the CNC/NC/PLC unit and the 2machine controller are physically included in the industrial machine, and the industrialmachine forms an independent and self-contained industrial machine system wherein the machine controller forms an essential and physically connected part ofthe machine.
A CNC system may be defined so as to comprise a machine tool, herein referred to as amachine, a part program, which is a detailed set of commands followed by the machine, and amachine controller (or machine control unit), which is a computer that stores the program and executes its commands into actions by the machine tool.
I/lanagement, control and monitoring of operations performed by an industrial machine needexpertise and experience from a machine operator as well as software-based support systemsto work out. To generate a program for the operation of for example manufacturing aparticular metal product, the program needs to be based both on a set of predeterminedprinciples, such as the calculation of operating sequences based on optimization techniques orshortest path principles, but also an operator's know-how ofwhat will be the best sequencefrom a more practical point of view. Variables to consider and control may be related tomaterials properties, logistics and of course to the actual geometries, shapes, dimensions and order in which products are to be produced.
Prior art technology discloses the establishment of machining or cutting programs which arebased on the principle that of single parts are produced as individual units. A wide variety ofconventional production methods are used for this purpose, such as cutting, punching and/orpressing. Here, production metrics to be applied for the cutting, punching and/or pressingoperation are defined in advance. Individual definitions are made for each part and applicable safety distances between adjacent parts are defined for each individual pa rt.
I/|ore recently, the so-called common cut technology has evolved as an improvement to themore conventional cutting techniques. The underlying technique for the common cuttechnology is based on dividing a workpiece by cutting two adjacent parts, the parts beingseparated by a distance corresponding to the width of a cut ofthe cutting beam. Hence,careful consideration must be made, when positioning shapes to be divided from each other,to the width of a cut of the cutting beam, given the prerequisites for that particular cutting operation. 3 Prerequisites for a cutting operation are to be determined already in connection with initialpreparation for and positioning of shapes to be separated along the cutting path. ln particularfor partially or fully automated processes, careful planning of a common cut machiningprocess is crucial. To realize that common cut cannot be used first after having positionedworkpieces for cutting, is too late, since the workpieces cannot be rearranged any more. Torealize that common cut could not be used even later, i.e. after the cutting operation hastaken place, inevitably leads to deformations and damage to the produced parts, and hence to cassation of produced items.
The above described common cut technique could also be applicable to for example punchingor pressing operations, provided that the common cut technique allows parts to be separatedfrom each other without causing damages or deformations, and does not cause thedimensions and quality of the produced item to exceed acceptable tolerances according to specification.
International patent publication WO 2011/042058 discloses a method and a system formachine cutting several parts out of a piece of material using a beam cutting technology. A setof controlling rules and variables are applied for forming a cluster of parts with free formshapes, the parts being positioned so close to each other so that only the thickness of one cutfrom the cutting beam is found between adjacent parts whenever the shape ofthe parts allows it.
Since the introduction of free form shapes in cutting operations, the market has quicklyrealized that the technology has a potential to noticeably increase productivity in sheet metalworking processes. One of the first advantages noted from free form cutting is the saving ofvaluable process time during cutting operations, which is one of the top priorities forcompetitiveness in production industry. Another advantage provided by the free form shapecutting is that it ena bles the shapes subjected to cutting to be arranged in a tighter pattern,thereby significantly reducing material waste, which is of benefit both from an industrial and an environmental perspective.
However, common cut technology, also when used in a way to allow for highly efficientproduction of free form shapes, may inevitably cause minor defects to the workpieces when in operation. Those defects are difficult to completely avoid and need to be considered, in 4particular for machining operations involving common cut technology. Tagged segmentsand/or defects that will eventually appear as a result of the machining operation are takeninto account already during the initial planning of an industrial machining operation in order not to impede the overall productivity of the operation.
Machining operations of today are based on default data and theoretical parameters, whichare stored locally in a database and calculated in advance ofthe operation. Various steps in atypical machining operation are therefore individually adjusted sequence by sequence. ln viewofthis, a related problem that needs to be at least considered when setting up and performingan industrial machining operation is the large number of dynamic variables that may have aninfluence on the operation. Some ofthose variables may otherwise adversely affect theefficiency, precision, quality and productivity of the industrial machining operation, whetherthe variables are related to logistics, materials properties, production quality, presently used tooling, available tooling or operators' needs.
SUMMARY OF THE INVENTION lt is therefore an object ofthe present invention to alleviate the mentioned problemsassociated with prior art technology by providing a method, an industrial machine system, acomputer program product and a non-transient computer-readable medium for selectingoptimum operation performance criteria for a metal working process, said method comprisingthe steps of: providing a process model that relates process parameters for the operationwith performance variables for said operation, wherein the process parameters andperformance variables are retrievable via integrated multiple data sources, selecting at least one optimization technique to define a function, said functioncomprising process parameters, generating the function for optimization by using acceptable tolerances of aproduct to be machined as a basis to define ranges for performance variables along withranges for process parameters, and applying the at least one optimization technique to said function, whereby optimum operation performance criteria are determined for the process model including 5process parameters and performance variables to obtain a set of requirements to be used for controlling the metal working process.
The optimum performance criteria calculated for the process model according to the above,result in a set of requirements which are transformed into operational instructions forcontrolling of an industrial machine. The control is typically executed by means of an industrialmachine program, comprising a set of operational instructions that instruct an actuator system to execute machining operations.
I/|ore in detail, some ofthe preconditions that differentiate the present invention fromtraditional solutions that have been described in prior art, is the full integration of systems,machines, information related to the fourth industrial revolution (loT) etc., but also of serviceproviders and customers. Full integration of various sources of relevant data enablesinformation relating to a metal working process to be retrieved even in real-time, andaccording to the present invention, this information may be analysed and utilized. The flexiblenature of the process parameters and the performance variables, and the dynamic utilizationof this information when optimising the metal working process, may lead to production resultsthat could never be obtained using a sequential analysis or optimisation as a basis for theproduction planning. The flexibility in process parameters may lead to a significant reductionof waste materials and/or production time (resulting from lesser tools changes etc.) and theflexibility in performance variables may lead to a lower overall production cost, which is beneficial to both the manufacturer and the customer.
By means of the present invention, significant advantages and benefits will be achievable inrelation to prior art technology some of which will be mentioned below. The dynamic natureof variables that may have influence and effect the efficiency and productivity of the industrialmachining operation, whether the variables are related to logistics, materials properties, tooling availability or operators' needs can be taken into consideration.
The present invention uses information retrieved from multiple sources, and stores suchinformation in a way that it is made available for use in connection with subsequent machiningoperations. By means of the retrieved information, the invention makes it possible to designand make available new or additional tools or tool geometries as required by the specific machining operation that is to be executed. 6ln accordance with one alternative embodiment ofthe invention, the method for selectingoptimum operation performance criteria for a metal working process comprises a process model, which is dynamically monitored and controlled.
This dynamic monitoring and control makes it possible to respond to variations in underlyingconditions for a metal working process over time. Underlying conditions could either be basedon technical properties that may vary over time, such as materials properties of for examplesheet metals, geometrical considerations and/or production process related properties, suchneed for exchange of tooling. Also other properties related to production planning may varyover time, such as production economy, order stock information, pricing, profitability,availability and related priorities. As a third category, properties related to the workingenvironment for an operator may be taken into consideration, such as operator availability,avoidance and heavy lifts for operators, less demanding manual tasks for operators duringnight shifts, such as machine reconfiguration, which are all properties related to the working environment that may vary over time. ln accordance with an alternative embodiment ofthe invention the method for selectingoptimum operation performance criteria for a metal working process comprises a processmodel, which is monitored and controlled in real-time to allow for dynamic adjustments in the pFOCeSS.
This has fundamental advantages in comparison with prior art, in particular for production ofrelatively small batches that require frequent adjustments and reconfigurations of processparameters. ln accordance with the invention, a reaction to outer variations may comeinstantly instead of having to wait for productivity evaluations. Those evaluations are oftenrecurrently scheduled manual calculations to be carried out as a follow-up of output fromalready completed production processes. The availability of information in prior art of today isinsufficient to be able to optimise production processes based on the present demand. Apossible optimisation of a production process is therefore oftentimes made too late to benefit from it.
According to the invention, the set of requirements to be used for controlling the metal working process can be provided as recommendations to an operator, who in turn may apply 7the set of requirements. As an alternative, the requirements may be applied with partial or no operator involvement.
According to yet another embodiment of the invention, the method for selecting optimumoperation performance criteria for a metal working process according to claim furthercomprises the step of: retrieving process parameters from multiple sources relating to the metalworking process, such as production order, product geometry and predefined tolerances,required metal working operations, required tooling configuration, stacking pattern ofproduced items, and/or process parameter data from previous operations, retrieving performance variables from different sources relating to the metalworking process, such as determined tolerances of produced items, process time, toolingavailability, machine availability, material availability, tooling lifetime, material removal rate,operator working environment, order stock, delivery time, required pressing position and/orperformance variable data from previous operations and/or performance variable data forsubsequent operations, storing the process parameters and performance variables in a consolidatedmemory in association with a computer system, such as an enterprise resource planning (ERP)system, and making the process parameters and or performance variables available for amachine controller or computing system for application of optimization techniques to select optimum operation performance criteria.
The plurality of process parameters are typically retrieved from different sources ofinformation, and a central computer (alternatively machine controller or computing system)may be configured such that it is connected or at least is connectable to these sources ofinformation. The sources of information may be very different and could be considered to be end-points in the machining system.
Process parameters are predefined parameters which typically relate to what is to beproduced, what is the order size, which are the optimum machining operations to beperformed so as to achieve predefined product geometries Also optimum tooling utilisation for machining and predefined tolerances ofthe produced items are process parameters. 8 Performance variables on the other side are data relating to the hypothetical result shouldother than optimum machining operations or optimum tooling configurations be used. lt isalso measured data from previous and/or currently and/or subsequent performed operations,which can be used as a basis for decision making, when a number of different variables are tobalanced and the machining process is to be optimised. Optimisation can be made based onany variable, such as for example production cost, production time, quality and product precision, operator working conditions, material waste or any combination thereof.
An example of the advantages of the invention is that tooling configuration to be exchangedbetween subsequent operations can be minimised. Experiences from prior operations can beused to determine whether a present tooling configuration is sufficient for achieving aparticular geometry, and whether the produced geometry will be within acceptabletolerances. Another example is that precision can be increased by avoiding tooling contacts with certain areas on items produced which may contain defects. ln accordance with an alternative embodiment of the present invention, tools and/orproduced items are embedded with electronics, software, sensors and/or networkconnectivity. This connectivity, often referred to as Internet of Things (loT), enables theobjects to exchange data, such as process parameters and/or performance variables, with thecomputer system and/or the computing system. When making an inventory of currentlyavailable tools for a certain machining operation, the computer system may then have instantaccess to updated information on which tools can be used and which cannot, for example due to being used for another machining operation of higher priority.
According to the invention, a surveillance unit is provided, such as a camera or other imagecapturing means, to detect presence and nature of various defects and/or visual attributes,bulges and/or other asymmetrical attributes created by a bending operation, so as to avoidtheir interference or any effects derivable from symmetry imperfections when stacking parts.Detailed information on those defects or visual attributes are retrieved, stored and madeavailable when determining a set of requirements to be applied in a process model for a subsequent metal working process. lt is made possible to adapt the pressing position or pressing pressure exerted on a sheet metal product to individual batch differences in properties between sheets metals of the same 9specification. The pressing position or required pressing coordinates are used to preciselydetermine whether the pressing pressure exerted is sufficient to reach the predefinedposition, i.e. a predefined coordinate in space, to which the tools is intended to reach.Retrieving and using process parameters also enables an increase in precision by avoiding tooling, clamping and gripping contacts with less defined areas on items produced.
Among the most valuable advantages ofthe invention is that information already present in aso-called resource planning system, a business management system which is available invirtually any industrial company, workshop or enterprise, is used to manage and control theindustrial machining system. Using this management system for logistics, production,inventories, maintenance, sales, etc., i.e. one or more systems in which all information isavailable and the dynamics ofthe business operations conducted are reflected, all aspectsinfluencing the productivity and with relevance to its customers into consideration can betaken into consideration. Such information may even include order availability, customerpriorities and pricing information, besides all information related to material properties, batchnumber, requested dimensions, shapes, tolerances, locations and various machining pa FameteFS.
The present invention hence brings together information that is, or could be, contained in anenterprise resource planning system with all requirements and the huge potential efficiencyenhancements of modern machining systems, so as to significantly improve the productivity incertain segments ofthe production industry. The dynamic monitoring and control allows theproducer to decrease batch sizes during production and in a near future allows the producerto immediately respond to short-lived variations in the demand. The present inventionprovides at least a first step towards the industrial vision of production of unique items and on demand.
BRIEF DESCRIPTION OF THE DRAWINGS Various embodiments and examples related to the present invention will now be described with reference to the appended drawing, in which: Figure 1 is a flow chart that depicts an optimisation of an operational sequence of an industrial machine system by monitoring, controlling and adjusting the sequence.Figure 2 graphically illustrates an industrial machine system according to one embodiment.
Figure 3 displays another embodiment of an industrial machine system according to the invention.
DETAILED DESCRIPTION The present invention relates to identification of part geometries, generation of a program forcontrolling an industrial machine system. lt also concerns configuration of an industrialmachine system, in particular an industrial machine system for metal working, such as a punchpress, press-break or bending machine. Combinations of punch presses and beam cuttingmachines are also conceivable for use, since such combinations are suitable also for millingand turning operations, besides cutting. Moreover, the invention relates to automationequipment and utilisation of process data obtained during previous machining operations,which data is used as input when planning, configuring, executing and managing a subsequent machining operation.
Both the detailed description and the drawings to which it refers are given by way of example only. Same reference numerals from different figures refer to the same element.
Sheet metal working is a generic term applicable to machining operations generally. Cutting,which is one ofthe comprised types of operations, is in this context to be construed as amachining operation executed by any of a variety of industrially applicable technologies,including cutting by means of technologies as laser, flames, plasma, waterjet, ion, air as wellas cutting by pressing, punch pressing and press-breaking. Milling, drilling and turningoperations also belong to sheet metal working, provided the operations relate to machining of sheet metal.
Several properties of sheet metal materials, previous logistics operations and machiningoperations influence the behaviour ofthe material during processing. Hence products manufactured by a machine using an identical program ofoperation are influenced by the 11manner in which the processed material has been previously handled. Most of those physicalproperties ofthe material can be determined in advance of the processing, and thereafterretrieved and stored by an enterprise resource planning system. Here the data related tophysical properties ofthe material to be processed is made available for use when planning and optimising machining operations.
Material-oriented properties that vary between subsequent operations are material quality,material compositions, size, shape and production batches that each clearly influences theresult and precision achieved during a machining operation, whether it is bending, punching, cutting, milling, drilling, turning etc.
One ofthe mentioned influential properties is the sheet rolling direction, a variable that isdependent on the prior logistics operations ofthe material. The sheet rolling direction mayhave a significant impact on the result of a bending operation. Another property is rotation ofparts and mirroring of the sheet metal, whereby rotation and mirroring of identical parts indifferent directions may have an influence on bending angles for otherwise identical parts.Bending angles may vary as much as by several degrees between two subsequent bendingoperations. The same is true for other machining operations, such as for beam cutting andpunching, whereby rolling direction, part rotation and mirroring may cause tension orexpansion of the material. All of the above variables are dependent on the prior logistics of the material.
The processing also influences the workpiece. During machining by means of punch pressing,the pressing operation generates marks that vary between punches of subsequent toolsstrokes. Another imperfection is the use of so-called micro joints when punching or pressing to fix parts with a surrounding skeleton or to fix several parts to each other.
When applying beam cutting it may be necessary to define a starting point, a so-called lead-in.Micro-joints are generated by closing the cutting path which surrounds the geometry of thepart. As previously mentioned, common cutting techniques and clustering of free form shapesmay generate different types of marks from tangential points, different types of lead-ins anddifferent types of micro-joints that occur between parts and the surrounding skeleton orbetween adjacent parts. All of the mentioned marks, lead-ins, micro joints can be seen as part defects or visual attributes. They are all departures from the original drawings, and provided 12 their existence and positions are known in advance of a machining process, the presentinvention provides a way to completely avoid them and or at least to alleviate any negativeinfluence from them. A first machine operation may have left defects and/or visual attributes,such as hardened or irregular surfaces etc., which makes it even more important for asubsequent machine operation to avoid them in order to protect applicable tooling from being da maged and thus increase its lifetime.
Segments, which are not allowed to comprise any part defects or visual attributes may bemarked. This way of marring, managing and avoiding imperfections is called tagging. As aresult of marking segments to be avoided, the industrial machining system will not place anylead-ins, micro joints, tangential points or other part defects or visual attributes on thesesegments. This allows for enhanced part quality and process reliability all through the valuechain but also results in increased volumes of scrap, i.e. materials waste. Scrap is undesiredand would limit the availability of techniques as common cut or clustering of free form shapes, which would otherwise be a means to enhance the productivity of industrial processes.
Tooling, i.e. a set of suitable tools for executing a bending program, or other machiningprogram, can be chosen both manually or automatically. A commonly used method for placingthe workpiece in a precise position before executing for example the bending operation is toposition axes of actuators as required. Back gauge, clamping mechanisms or fixtures are usedto more accurately position and support a workpiece before the bending operation isexecuted. All ofthe above machine configurations and support arrangements generate data,which is collected. Also cutting heads, nozzles, lenses and related optics equipment relating tomachining operations generate data that can be collected, provided as feedback and thus taking part in an optimisation of machining operations.
Bending angles and/or back spring can be measured both manually and automatically bymeans of for example laser, optical, mechanics. Automation units are configured to support anoperator to move the workpiece so that sequencing and bending operations can be executed.Processed parts are stacked manually and/or automatically after machining operations havebeen executed. Stacking is made prior to customer delivery according to a number of guidingprinciples, some of which are related to operational efficiency, some ofwhich are related to logistics and some of which are related to customer needs. 13 The present invention relates to generation of a machining process, such as a program forpunching, combinations of punching laser, milling, drilling, turning and/or bending, and takesinto consideration information from the previous operation in sheet metal working. Theprogram optimises tooling configuration, through minimising required tooling exchange froma previous operation, minimising the number of tools required and the movements of tools.The program also minimises the motions required so as to reduce cycle time, applicable for anoperator and/or automated process. The effort required for an operator to move a workpieceis also considered, which means that the shortest path does not always require the leasteffort. With reference to figures 2 and 3, the machining program could be made directly on the machine or disconnected from the machine depending on its configuration.
Collisions between a workpiece and the machine and tooling applied, is also considered.Conceivable is to allow collisions to be simulated manually or automatically before executing the program on the machine.
Figure 1 is a flow chart that depicts an optimization of an operational sequence in an industrialmachine system or a manufacturing support system, possibly remote in a central computerwhich is connected or at least is connectable to multiple sources of data. The system may beconfigured to provide support for business operations relating to design- and constructionprocesses (including the option of parametric design), selection of material, purchasing,logistics etc., by inputting desired parameters followed by modifying and presenting the optimum performance criteria.
The sequence starts (S10) in that an operator or client either manually or automatically inputs(S20) desired parameters relating to a product to be machined or evaluated. This input ofdesired product parameters can be made at any location. One example is that an application(app) developed for a mobile terminal, such a so-called smartphone, is used as a tool forrealizing the input of desired parameters. This app may then be provided to all stakeholdersalong the value chain, for example designers, purchasers, logistics professionals,manufacturing specialists etc. ln a next step, the computing system according to the invention generates (S30) resulting operational data based on the desired process parameters. ln a first step (S10), the process model is provided (pre-loaded) (S20) with process parameters relating to a previous sheet metal working operation. 14ln a second step, identification (S30) is made of clamping mechanism, gripping configurations and tooling locked up, i.e. currently applied settings, configurations and tools in the machine. ln the next step, analysis is made ofwhether the current tooling configuration can be used toeffect a complete machining operation of next batch for production (S40), such as a bendingoperation of parts for subsequent production. An evaluation is also made ofwhether the current tooling configuration could be improved given an available workpiece for production and its process parameters.
Based on pre-loaded information, also the product geometry is analysed, so as to determinewhether an adjustment to the geometry within acceptable tolerances, would be possible toproduce given the current set of tooling. Moreover, the tooling available for exchange isanalysed, so as to determine whether the original or alternative product geometries, asmentioned still within acceptable tolerances, would be possible to produce given the availabletooling. Based on the above information and process optimisation, it is hence determinedwhether to keep current tooling configuration, adjust the product geometry within toleranceboundaries or exchange at least one tool to execute the currently applicable machiningoperation (S50, S60, S65). Calculation is also made of the optimum tooling configuration based on tooling availability.
Based on pre-loaded information, it is further determined whether to exchange and/or adjust the back gauge, clamping mechanism and/or fixture (S70), either manually or automatically.
Based on pre-loaded information, calculate whether to exchange and/or adjust gripping toolsthat position parts for machining (S90) and for suitably also for a subsequent stacking ofproduced parts. Calculation ofthe optimum gripping tools is used as a basis for arecommendation of manual adjustments and/or exchanges, which are presented to anoperator. Alternatively, partly or fully automatic adjustments and/or exchanges may be executed by the machine with little or no active involvement of an operator.
The determination of whether the current machine configuration enables production of anitem according to its process parameters (S40) also includes determination of other enablingrequirements besides the tooling configuration. Examples ofthe requirements may be missing spare parts, missing tooling, need for maintenance, material quality, shape, dimension and/or material of a part to be manufactured. Process parameters and performance variables relatingto the requirements are stored in the computer system, the computing system and/or acentral computer which is connected or at least is connectable to a plurality of sources ofdata, and in connection with the machine. The requirements relating to a process to beexecuted may be responded to by issuance of a purchase order or operator recommendation.Such a purchase order may be issued automatically, i.e. without direct involvement of anoperator, or as a recommendation presented to an operator, who is to execute the orderaccordingly. ln case a production process results in products outside ofthe tolerancelimitations, a supplementary production order may be placed without direct operator involvement so as to meet customer demands on quality and precision in the delivery.
Parts are identified before the machining operation by using any known identification method,such as computer vision or other image capturing technology, to identify geometries, defects and/or engraved, marked or other visual attributes of parts to be machined.
Back gauge, clamping mechanism and/or fixture are configured to avoid defects and/or visualmarks from the previous operations from coming in direct contact with the back gauge. Thisallows the workpiece to be positioned correctly and in direct contact with its support whenexecuting bending operations. Moreover, bending pressure is adapted so as to generatecorrect bending angles based on data from prior operations, by means of using a bendingangle measuring system which is provided with feedback from prior operations, whereby every bend produced has an angle within acceptable tolerances.
Required attributes described above, i.e. composition, batch, sheet rolling direction-rotation,part rotation, part mirroring, clustering, common cut, lead-ins, micro joints, etc. arecontinuously monitored. ln result of detected variation of any of the attributes, processparameters, i.e. bending position, bending pressure, crowning data, angle measurement data,back spring measurement data, positions of back gauge, clamping mechanisms and fixture,tools radius compensation, tooling condition etc., are correspondingly adjusted to ensure acorrect position of the workpiece and machining resulting in parts with acceptable tolerances.By crowning is here meant a technique used to compensate for deviations along a bending line. 16Parts may be visually inspected after the bending operation to identify geometries incombination with defects, visual attributes, such as bending lines, bulges and/or asymmetriescreated by the bending operation. ln result of the identified defects or visual attributes,stacking of parts may be made to avoid placing defects between parts thus affecting the symmetry of the stack. ln parallel with the generation of operational data, the computing system (or centralcomputer), which is be connected to or at least is connectable with plural sources of data,selects (S40) at least one optimization technique to define a function, a function whichcomprises the desired process parameters. This is followed by generation (S50) of a functionfor optimization by using the desired process parameters as a basis to define ranges for performance variables along with ranges for process parameters.
The generated function for optimization is applied (S60) whereby optimum operationperformance criteria can be determined for the process model including process parametersand performance variables to obtain a set of requirements to be used for controlling the metal working process.
As soon as the optimum performance criteria have been determined, the resulting operationaldata is compared (S70) with the optimum operation performance criteria, and in case there isa difference, and the optimum performance criteria seems to provides a performanceadvantage to the operator or client, the result is presented (S80) to a decision-making entity.This decision-making entity, whether being a human operator, a computerised, fully or semi-automated service layer, is allowed to modify (S90) the desired process parameters based onthe presented optimum operation performance criteria for the metal working process. Thedecision-making entity may also be realized in the form of an application (app) for asmartphone, preferably the same or an app similar to the one mentioned in connection with the step of inputting desired parameters. |fthe decision-making entity decides to modify process parameters comprised in thepresented information (Yes), the proposed operational sequence is adopted by the industrialmachine system. ln case the decision-making system decides not to accept the proposal (No),the sequence continues in that the originally generated operational data is applied (S100).
Whichever decision is made, the sequence continues to the starting point (S10) or end point 17(S110). I/|odified data may further be used in different applications such as CAD, CAM, ERP,I/IES, CRM, Sourcing management etc. The present invention is also applicable within areassuch as purchasing and optimization of machine performance criteria, criteria which may bedefined as instructions and/or a program of instructions for the control an industrial machine, such as a CNC machine tool.
Figure 2 graphically illustrates a first embodiment of the invention. The system comprises amachine 1, which may be a machine for beam cutting (2- or 3-dimensional), punching, punchpressing, press-breaking, bending, gluing, sewing, tape and fibre placement, milling, drilling,turning, routing, picking and placing and combinations of such machines. Beam cuttingincludes techniques such as laser, welding, friction stir welding, ultrasonic welding, flame and plasma cutting, pinning and sawing.
The machine comprises an actuator system 2 for performing an industrial operation. Theactuator system comprises at least one actuator, i.e. a motor for linear or rotationalmovement. Typically, the actuator system is configured for performing two-dimensional orthree-dimensional movements of an operational part of the machine and a workpiece relative to each other.
The actuator system is controlled by an actuator controller 3 in the form of a CNC/NC/PLC unitand/or related sensing and processing equipment. The actuator controller controls theactuator on a low level, i.e. by sending low level control commands for the actuation of theactuator system. The actuator system is connected to the actuator controller via a machine internal communication network 4, e.g. including a communication bus.
The machine optionally comprises other systems, such as a sensor system 10 for sensingvarious processing parameters of the machine and other controllers 11 for processors,networks, communication links or other computing devices for transmitting data and makingdecisions. These systems may also be connected to a machine common internalcommunication network 4 and to the computing system in connection with the machine, suchthat the machine controller is connected to the sensor system to receive sensor data. Themachine controller may be further configured to remotely control the actuator system ofthe machine in response to the sensor data. 18 As an alternative configuration, the CNC/NC/PLC unit and/or related sensing and processingequipment as well as the mentioned machine controller may be physically attached to orotherwise included in the industrial machine. The industrial machine then forms anindependent and self-contained industrial machine system, wherein the machine controllerforms an essential and physically connected part of the machine. Both of the two alternativeembodiments of industrial machine systems have their respective advantages, and for thepurpose of the present invention, integrated or remote configurations of sensor system and actuator controller are both equally applicable.
The machine may also comprise a communication client 5 connected to the actuatorcontroller 3 for establishing communication with a computing system 6 in connection with themachine, when configured according to the remote alternative. The communication client isthen a functional unit which enables the machine or any sub-component of the machine tocommunicate with the machine controller. The computing system in connection with themachine may be a cloud-based computing system connected to the internet. A centrallyarranged computer in connection with or connectable to a plurality of data sources is analternative embodiment. The communication client 5 and the computing system in connectionwith the machine may be configured to establish secure communication 7 with each otherover the internet, for instance by initiating encrypted communication by HTTPS/TSL or byestablishing a VPN (virtual private network). Alternatively, the communication may beestablished over a firewall or a proxy server 8. As a further alternative, any sub-component ofthe machine, such as the actuator controller 3, may be configured to connect to thecomputing system 6 in itself, or alternatively to the mentioned central computer with accessto multiple data sources, but as mentioned both remote and integrated configurations are equally applicable for this purpose.
The mentioned computing system 6 in connection with the machine comprises a machinecontroller 9, wherein the machine controller may be remotely connected to the machine, andwherein the machine controller may be configured to control the actuator system of themachine remotely via the actuator controller by modifying operational parameters of the actuator controller. 19 The machine controller 9 is hosted in a virtual machine in the remote computing system 6. lnthat way the machine controller resource may be exploited in an efficient way. The machinecontroller may e.g. be configured to read and execute machine program code, controlmachine parameters, allow manual control or adjustments of machine parameters, andfunction as an interface to associated systems. The machine controller is connected to a HMI(Human-Machine Interface) unit 12 which may be remotely connected to the machinecontroller via an internet connection 13 and in another embodiment is integrated with themachine. Either way, an operator of the machine may supervise and control the operation ofthe machine from a remote location, e.g. connected to the internet. The HMI unit 12 and/orremote computing system 6 may be configured to require user identification of an operator, e.g. by requiring passwords or other identification means.
One alternative embodiment of the invention as illustrated in figure 2. Locally on the machine1, an actuator system 2, comprising actuators for performing machining operations isincluded. An actuator controller 3 is part of or connected to the actuator system 2. Theactuator controller is configured to receive instructions from the remote machine controllerand execute instructions block by block in a closed loop system. Each task performed by anactuator is hence monitored and after a completed sub-operation, the actuator will performthe next sub-operation until a whole operation is completed. This means that the operation ofthe actuators ofthe machine is controlled by the actuator controller on a low level. Theactuator controller typically includes a memory and a processor in order to save and executeinstructions and to log data. The actuator system does not involve a conventional machinecontroller or HMI. The actuator system of the machine is hence dependent on receivinginstructions from the remote machine controller. Once a complete set of work instructions ora defined sub-set thereof have been received and verified it may however be executedwithout further instructions from the machine controller. A sub-set of work instructions maybe a part of a complete machine operation, but at least involves enough information for theactuator system to perform a part of a complete operation. The operation is preferablyperformed step by step in a closed loop system within the machine. The machine is onlyfurnished with simple functions such as an emergency stop button and an on/off button.Other than that the machine is dependent on commands from the remote machine controller tO Opefate.
The machine controller is physically located remote from the machine, typically in the cloud.The monitoring of an ongoing process, loading of instructions, modification of instructions andcreating new instruction may only be made at the remote machine controller. Hence, theinventive machine controller corresponds to a conventional machine controller, only it is not aphysical part ofthe machine but remote connected to the machine. The instructionsmonitored and controlled by the machine controller and the interconnected HMI include operational parameters such as cutting velocity, cutting depth, pressure and so on.
The machine controller is not part of the closed loop system ofthe actuator controller. Hence,unless new instructions are sent from the machine controller, the actuator system at themachine will conclude a fully received operation instruction without awaiting furtherinstructions, unless specific instructions to conclude or alter the operation are received fromthe machine controller. Typically though, instructions are only provided for a full operationand new instruction will therefore only count for subsequent operations, not ongoingoperations. This may be set as a safety arrangement but is up to the operator to decide which type of operational security should be implemented.
The machine controller is configured to send instructions, instruction per instruction, orseveral instructions in a batch system. Any conventional manner of sending information maybe utilized. The machine controller is further configured to receive information and makedecisions based on said information. For example, the machine controller may act on feedback data and make decisions and/or send new instructions based on said feedback.
The inventive system provides for a possibility of remote controlling of an industrial machine,without risking that commands are lost as a consequence of bad communication due to forinstance latency in the internet connection. This is made sure e.g. because an operation is received and acknowledged in full at the actuator controller. ln order to facilitate surveillance, the machine comprises a surveillance unit 14, such as acamera, video camera or other image capturing means, for monitoring operations by themachine. The surveillance unit is connected to the remote computing system 6 via the communication client 5 and configured to provide operational information to the remote computing system. The operational information is processed and transmitted to the HMI 12. 21The machine controller is configured to receive a machine program from a CAD/CAM system or by manual entry from an operator, e.g. via the HMI unit 12. ln one embodiment the remote computing system is configured to monitor an operationalparameter ofthe machine, and disable the remote control of the actuator system ofthemachine by the machine controller when the operational parameter exceeds a thresholdvalue. Such an operational parameter may be the operating time, the number of operationalcycles performed by the machine etc. Thus the operational costs and the use ofthe machine may be controlled and limited by limiting access to the machine controller.
The remote computing system is configured to collect machine and/or production data andtransfer the data to another system (not shown) for data analysis and/or optimization. Themachine data may be used to e.g. optimize the supply chain (purchase, manufacturing,distribution), the demand chain (marketing, sales, service), machine maintenance or for other big data applications.
The surveillance unit may also be configured for monitoring produced items and their variousproperties, including their tolerances. Computer vision is another term used in the industry forthis identification of properties related to geometry. By tolerances is meant materialproperties, such as hardness, toughness, size, shape, product geometries, such as radii, anglesand dimensions, and production defects, such as, bulges, bending lines, pressure deformationsand/or other visual attributes. The surveillance unit may further be connected to thecomputing system 6 in connection with the machine, via the communication client 5 and configured to provide operational information to the computing system. ln one embodiment the computing system in connection with the machine is configured tomonitor an operational parameter ofthe machine, and disable the remote control of theactuator system ofthe machine by the machine controller when the operational parameterexceeds a threshold value. Such an operational parameter may be the operating time, the number of operational cycles performed by the machine etc.
The computing system is configured to collect machine and/or production data and transferthe data to another system for data analysis and/or optimization. This system may be an enterprise resource planning system (ERP) of manufacturing execution system (I/IES) of any 22kind. The machine data may be used to for example optimize the supply chain, i.e. purchase,manufacturing and distribution; the demand chain i.e. marketing, sales and service; andmaintenance of the machine or its integrated or remote parts. I/|achine data may also bemade available for other systems, such as big data applications designed merge data and draw conclusions based on very large amounts of information.
Figure 3 displays an alternative embodiment of an industrial machine system according to theinvention. The industrial machine system differs from what is described in relation to figure 1in that the machine does not comprise an actuator controller. The actuator controller 3' isphysically disconnected to the machine and comprised in the computing system 6 inconnection with the machine. The computing system is connected to the machine via one ormore data lines 7, e.g. over the internet, which may be encrypted. The machine 1 comprises atleast one communication client 15 for establishing communication between the machine andthe computing system 6 in connection with the machine. This communication client 15 isconnected to the actuator system 2 of the machine, and thus called the actuator client. Theclient is configured to send and receive low level communication from the actuator controllerto the actuator system. Similarly, the machine may optionally comprise a sensorcommunication client 16 for communicating any sensor data from the sensor system 10, andany further controller clients 17 for communicating with other controllers 11 in the machine.Similar to what is shown in relation to figure 2, the communication between the machine andthe computing system in connection with the machine may be the established over a firewall or a proxy server.
Below will follow examples of the present invention, intended to further elucidate thefunction and working principles. As has been explained in connection with the background ofthe invention, traditional processes of production planning in accordance with prior art aresequential to their nature. This means that information to control a sequence is collected froma local database, and the production planning is made in response to instructions emanatingfrom locally stored information. An example ofthis could be 1) retrieve an order, 2) select orcreate at least one controlling algorithm, 3) produce a part of a certain raw material quality,and 4) form a certain component by means of bending, milling, turning, etc., 5) deliver thecomponent to a customer according to order specifications. As mentioned, this process is sequential, and data to control the process is collected from a local database. 23The present invention, as has been previously described, utilizes various sources to collectinformation via the mentioned central computer, such as a batch of orders includinggeometric drawings, a batch of material, a batch of tools and a machine's existing configuration.
Information relating to the production process according to this specification generally comesfrom different sources, e.g. an ERP/MES, the machine, |oT information, CAD/CAM and one ormore surveillance units. The information collected by means of a central computer, which isconfigured as an intermediate means, that is situated in-between various end-points. The end-points are typically sources of information that may or may not influence a productionprocess, and are comprised of for example the previously mentioned ERP/MES, the machine, |oT information, CAD/CAM and surveillance units.
The central computer may either be a general purpose computer or the computer that isconfigured to function as the machine control. The central computer will always be connected,or is connectable, to at least two end-points comprising data, in order to obtain informationsubject to optimization. That is believed to be a minimum requirement in order to carry outand fully accomplish a non-sequential optimization process on multiple variables. Severalmethods of optimization may be used, based on combinatorics, dynamic variation,multivariate analysis etc. Any of the methods allow for non-sequential and non-linearoptimization, and are well-suited for use in complex systems with large numbers of dynamic variables.
The present invention utilizes non-sequential optimization, which is a numerical process ormethod that is neither sequential nor linear as compared to traditional processes. Several ofthe steps in a production process may be subject to optimization. One example is geometry ofparts to be produced, a geometry that may be modified to reduce tool changes, anotherexample is scheduling jobs may be altered to reduce setup time provided that information isretrieved from for instance a machine, a surveillance unit and/or from |oT informationsources, third and fourth examples are scheduling jobs that may be adjusted to reducematerial changes, provided that information is gathered from at least two end-points, andinformation that can be read and reused from previous process steps, e.g. visual attributes via a surveillance unit or modification of tool combinations or the rotation of a part on its surface. 24Other conceivable examples are to reconfigure machine tools, such as the back-gaugepositioning, pressure, pressing position etc. or the ordering of tools, materials, maintenance, spare parts for reducing production disruptions.
One of the prerequisites to making this type of optimization is to allow retrieval of data from avariety and a plurality of sources e.g. ERP/MES, the machine and its configuration, |oTinformation, CAD/CAM, surveillance unit. Information is then collected in and made availablefrom the central computer in order to allow for optimization of several separate process stepsin relation to their current status, including dynamic influences that are not controllable, since being dependent circumstances on out of reach, such as updates in a management system.
The present invention may also introduces control of the so-called modifiability andcustomizability in various end-points (data sources), such as ERP/MES, the machine and itsconfiguration, |oT information, CAD/CAM (both with respect to design and configuration) andat least one surveillance unit. For example, by means ofthe present invention, it is possible tochange the materials specification as a measure to potentially reduce material and toolchanges, the mandatory tolerance intervals and relevant ranges of strength and solidity. lnaccordance with another embodiment of the invention, it is also possible to change theproduct geometry/shape to minimize tool changes but still maintain tolerances from drawingsor as an alternative, on which coordinates visual marks exist that can be back gauge positionedfor complete avoidance. Is may also be possible to schedule jobs to reduce material/toolreplacement while keeping the delivery time. This allows communication with the customer soas to possibly allow the delivery time to be a variable influencing the price of the produceditem. ln order to achieve those options and new opportunities, two or more end points mustbe able to control in a non-sequential fashion, e.g. via the machine tool, via |oT informationand a database in ERP/MES to schedule orders, tools, materials change, change productgeometry. For instance, an amendment to the geometry that may lead to a reduction orminimization of tool changes can be checked against any form of tolerance interval in adrawing that can be available in ERP/MES or even available at a customer or designer as a variable influencing the ration between production cost and market price.
As has become apparent based on the above, the present invention is differentiated from traditional prior art process planning by means of MES systems of production scheduling that are configured to retrieve information from a local database. Those systems may even bebased on the functionality that an operator keys in data on orders and delivery, which isfollowed by sequential scheduling. The present invention is based on an entirely different levelof optimization based on actual, even real time data, a central computer that retrieves, acomputer that also in some cases may share information. The central computer is connectedor connectable to two or more end points, such as ERP, I/IES, CAD, CAM, machine, |oTinformation sources, at least one CRM management system and/or surveillance unit. lnaddition to that, the central computer may also be connected or connectable to otherproviders of information relating to multiple variables influencing production, such asmaterials, tooling, spare parts, maintenance, design, specification or customers of parts, constructions and/or products.

权利要求:
Claims (22)
[1] 1. A method for selecting optimum operation performance criteria for a metal working process, said method comprising the steps of: providing a process model that relates process parameters for the operation 5 with performance variables for said operation, wherein the process parameters and performance variables are retrievable via integrated multiple data sources, selecting at least one optimization technique to define a function, said functioncomprising of process parameters, generating the function for optimization by using acceptable tolerances of a 10 product to be machined as a basis to define ranges for performance variables along with ranges for process parameters, and applying the at least one optimization technique to said function, wherebyoptimum operation performance criteria are determined for the process modelincluding process parameters and performance variables to obtain a set of 15 requirements to be used for controlling the metal working process.
[2] 2. A method for selecting optimum operation performance criteria for a metal workingprocess according to claim 1, the metal working process being any industriallyapplicable cutting technology based on laser, flames, plasma, waterjet, ion, air, 20 bending, pressing, punch pressing, press-breaking, milling, drilling and turning.
[3] 3. A method for selecting optimum operation performance criteria for a metal workingprocess according to claim 1, wherein the metal working process relates to machining of sheet metal.
[4] 4. A method for selecting optimum operation performance criteria for a metal workingprocess according to claim 1, wherein the process model is dynamically monitored andcontrolled, preferably in real time.30 5.
[5] 5. A method for selecting optimum operation performance criteria for a metal working process according to claim 1, wherein the set of requirements to be used for 27controlling the metal working process can be provided as recommendations to an operator or alternatively can be applied with partial or no operator involvement.
[6] 6. A method for selecting optimum operation performance criteria for a metal workingprocess according to claim 1, further comprising the steps of: retrieving process parameters from multiple sources relating to the metalworking process, such as production order, product geometry and predefinedtolerances, required metal working operations, required tooling configuration, stackingpattern of produced items, and/or process parameter data from previous operations, retrieving performance variables from different sources relating to the metalworking process, such as determined tolerances of produced items, process time,tooling availability, tooling lifetime, material removal rate, operator workingenvironment, order stock, delivery time, required pressing position and/orperformance variable data from previous operations, storing the process parameters and performance variables in a consolidatedmemory in association with a computer system, such as an enterprise resourceplanning (ERP) system, and making the process parameters and or performance variables available for amachine controller or computing system for application of optimization techniques to select optimum operation performance criteria.
[7] 7. A method for selecting optimum operation performance criteria for a metal workingprocess according to claim 6, further comprising the steps of: comparing retrieved process parameters (S20) relating to the metal workingprocess from previous operations with a current machine configuration (S30)comprising parameters relating to tooling, determining ifthe current machine configuration enables production of an itemaccording to its process parameters (S40), evaluating the applicability of the tooling configuration (S50), which whenrequired, in a first optional step results in adjustments to the product geometry (S60)within acceptable tolerances, and in a second step results in adjustments to the tooling configuration (S65), and 10. 28whereby any adjustments made result in a new current machine configuration to be compared with parameters from previous operations (S30).
[8] 8. A method for selecting optimum operation performance criteria for a metal workingprocess according to c|aim 6, further comprising the steps of: comparing retrieved process parameters (S20) relating to the metal workingprocess from previous operations with a current machine configuration (S30)comprising parameters relating to clamping mechanism and/or gripping configuration, determining ifthe current machine configuration enables production of an itemaccording to its process parameters (S40), evaluating the applicability of the clamping mechanism (S70), which whenrequired results in adjustments to the clamping mechanism (S80), and/or evaluating the applicability of the gripping configuration (S90), which whenrequired results in adjustments to the gripping configuration (S100), and whereby any adjustments made result in a new current machine configuration to be compared with parameters from previous operations (S30).
[9] 9. A method for selecting optimum operation performance criteria for a metal workingprocess according to c|aim 6, wherein tools and/or produced items are embedded withelectronics, software, sensors and/or network connectivity, which enables theseobjects to exchange data, such as process parameters and/or performance variables, with the computer system.
[10] 10. A method for selecting optimum operation performance criteria for a metal workingprocess according to c|aim 6, wherein predefined and/or determined tolerances ofproduced items include any of the following performance variables: material properties, such as hardness, toughness, size and thickness, product geometries, such as radii, angles and dimensions, and production defects, such as bulges, bending lines, pressure deformations and other visual attributes.
[11] 11. 2911. A method for selecting optimum operation performance criteria for a metal workingprocess according to c|aim 6, wherein product geometries includes data on bending curves, compensation factors and tooling preferences.
[12] 12. A method for selecting optimum operation performance criteria for a metal working 15. process according to c|aim 6, wherein identification of defects or visual attributes onproduced items are taken into consideration when stacking of workpieces following machining operations.
[13] 13. A method for selecting optimum operation performance criteria for a metal working process according to anyone of preceding claims, wherein the determination of whether the current machine configuration enables production of an item according to its process parameters (S40) in addition to the tooling configuration also includesdetermination of other enabling requirements, such as spare parts, tools,maintenance, material, shape and/or dimension, whereby corresponding process parameters and/or performance variables are stored.
[14] 14. A method for selecting optimum operation performance criteria for a metal working process according to c|aim 13, wherein stored process parameters and/or performance variables are responded to, preferably by issuance of a purchase order or operator recommendation.
[15] 15. A method for selecting optimum operation performance criteria for a metal working process according to anyone of preceding claims, wherein the method is adapted to be used in a computer numerical control (CNC/NC) or programmable logic controller (PLC) system.
[16] 16. An industrial machine system comprising: a machine (1) comprising an actuator system (2) for performing an industrialoperation,a computing system (6) in connection with the machine, comprising a machine controller (9), and
[17] 17.
[18] 18.
[19] 19.
[20] 20.
[21] 21.
[22] 22. the machine controller being adapted to carrying out the method according to anyone of claims 1-15. An industrial machine system according to claim 16, wherein the machine systemfurther comprises a surveillance unit (14) in connection with the computing system, forcapturing image information related to process parameters and performance variables of the industrial operation. The industrial machine system according to claim 17, wherein the surveillance unitcomprises an image, image sequence or video capturing means to identify partgeometries in combination with any visual attribute, such as engraved and/or markedattributes, part defects, bending lines, bulges and/or other asymmetrical attributes created by the machining operation. The industrial machine system according to claim 16, wherein the computing system(6) is configured to collect data and use the data for data analysis and/or optimization and/or transfer the data to another system for data analysis and/or optimization. The industrial machine system according to claim 16, wherein the machine system is a press-break or bending machine. Computer program product comprising computer program code, which when executedenables a processor in a computer to perform the method according to anyone of claims 1-15. A non-transient computer-readable medium or media comprising data representingcoded instruction sets configured for execution by a processor in a computer, the instructions comprising the method according to anyone of claims 1-15.

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同族专利:

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US20190030582A1|2019-01-31|

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KR20180118695A|2018-10-31|

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CN109074047B|2021-12-21|

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EP3417349A4|2019-10-09|

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US20210237136A1|2021-08-05|

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JP2019512770A|2019-05-16|

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EP3417349B1|2022-01-19|

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US11103909B2|2021-08-31|

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CN109074047A|2018-12-21|

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EP3417349A1|2018-12-26|

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