WO2016177582A1 - Procédé de fabrication de pièces formées et machine de formage pour la mise en œuvre dudit procédé - Google Patents

Procédé de fabrication de pièces formées et machine de formage pour la mise en œuvre dudit procédé Download PDF

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Publication number
WO2016177582A1
WO2016177582A1 PCT/EP2016/058864 EP2016058864W WO2016177582A1 WO 2016177582 A1 WO2016177582 A1 WO 2016177582A1 EP 2016058864 W EP2016058864 W EP 2016058864W WO 2016177582 A1 WO2016177582 A1 WO 2016177582A1
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WIPO (PCT)
Prior art keywords
forming
molded part
characteristic
section
measuring
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/EP2016/058864
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German (de)
English (en)
Inventor
Werner Steinhilber
Volker Kalkau
Claus Denkinger
Christoph Widmann
Julian Pandtle
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Wafios AG
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Wafios AG
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Filing date
Publication date
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Publication of WO2016177582A1 publication Critical patent/WO2016177582A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21F—WORKING OR PROCESSING OF METAL WIRE
    • B21F1/00—Bending wire other than coiling; Straightening wire
    • B21F1/006—Bending wire other than coiling; Straightening wire in 3D with means to rotate the tools about the wire axis
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D7/00—Bending rods, profiles, or tubes
    • B21D7/02—Bending rods, profiles, or tubes over a stationary forming member; by use of a swinging forming member or abutment
    • B21D7/024—Bending rods, profiles, or tubes over a stationary forming member; by use of a swinging forming member or abutment by a swinging forming member
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D7/00—Bending rods, profiles, or tubes
    • B21D7/12—Bending rods, profiles, or tubes with program control
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D7/00—Bending rods, profiles, or tubes
    • B21D7/14—Bending rods, profiles, or tubes combined with measuring of bends or lengths
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21F—WORKING OR PROCESSING OF METAL WIRE
    • B21F3/00—Coiling wire into particular forms
    • B21F3/02—Coiling wire into particular forms helically
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21F—WORKING OR PROCESSING OF METAL WIRE
    • B21F35/00—Making springs from wire

Definitions

  • the invention relates to a method for producing molded parts according to the preamble of claim 1 and to a forming machine configured for carrying out the method according to the preamble of claim 12.
  • Forming machines are machine tools which, with the aid of suitable tools made of semi-finished products such as wire or pipe or the like, can produce smaller or larger series of molded parts or individual shaped parts with partially complex geometry, predominantly by forming, in an automatic production process.
  • a forming machine may, for example, be a bending machine for producing two-dimensionally or three-dimensionally bent bent parts of wire material or tube material or a spring machine for producing compression springs, tension springs, torsion springs or other spring-like shaped parts by spring winds or spring coils.
  • Such a forming machine has a plurality of controllable machine axes, a drive system with a plurality of electric drives for driving the machine axes and a control device for the coordinated control of working movements of the machine axes in a manufacturing process according to a manufacturing-specific, computer-readable control program.
  • the movements of the machine axes are controlled in a coordinated manner with the aid of the control device in order to produce one or more permanent bends on the workpiece by plastic deformation.
  • the moldings are springs, e.g. Coil springs, arise u.a. Bends in combination with torsion in the form of turns or sections of turns.
  • the bending angle is the angle between the extended center axes of the adjacent straight line sections.
  • the magnitude of the bending angle corresponds to the angle of rotation which a rotatable bending tool has to travel in order to produce the desired bend in order to produce the bend or the bend by deformation in a straight workpiece section.
  • a bend can be further characterized by a bend radius, wherein the bend radius is the radius of curvature of a circular arc portion of the bend. Bending radius and bending angle are typical geometric parameters for characterizing bends of such molded parts.
  • the bent straight line section When bending metallic materials, the bent straight line section usually springs back after a bending process due to the elastic-plastic material behavior by a certain angular amount, which is usually referred to as springback angle.
  • the springback is usually compensated by the fact that the workpiece is over-bent during the bending operation beyond the desired bending angle desired for the finished bent part. Attempts are made to control the extent of overbending, which can be described by the overbending angle, so that the desired setpoint bending angle is present after springback.
  • the required overbend angle depends i.a. Material parameters and workpiece parameters and can be calculated workpiece-specific, e.g. based on parameters such as diameter, tensile strength and modulus of elasticity.
  • a characteristic curve may be stored, which determines the functional relationship, e.g. between a desired bending angle on the workpiece (target bending angle) and the necessary for its production, to be driven by the bending axis angle of rotation (feed angle) of the corresponding forming tool indicates.
  • the characteristic curve can first be calculated on the basis of workpiece and material parameters.
  • a method for producing molded parts from an elongate workpiece, such as in particular of a wire or pipe, by forming by means of a forming machine can then proceed so that at least one characteristic is specified, the functional relationship between a desired geometry parameter of the molding and a represents the delivery of a forming tool influencing the geometry parameter to achieve the desired geometry parameter, and that the infeed of the forming tool is controlled on the basis of the characteristic curve in a productive production of molded parts.
  • the user can still manually adjust the characteristic if required by entering correction values.
  • the operator can measure a manufactured molded part, the desired geometry of which corresponds to the desired geometry of the molded part to be produced later, by means of a gauge or other measuring aids and manually enter correction values for suitable support points of the characteristic, in order to produce an improved characteristic curve which is to be set up leads faster to good parts.
  • the published patent application DE 10 201 1 006 101 A1 describes a bending machine which makes it possible to determine the current actual value of the bending angle from the rotary position of a bending arm detected by means of a rotary encoder during the current bending process.
  • an automatic adjustment (correction) of the characteristic curve is performed if the result of the measurement shows that the angle of rotation of the bending arm determined on the basis of the current characteristic curve does not lead to the desired setpoint bending angle with sufficient accuracy.
  • This results in a dynamically changeable characteristic whereby the control of the bending machine can "learn" from each bending operation for the subsequent one, whereby, for example, gradual changes of workpiece properties can be continuously compensated for.
  • the problem of springback occurs in principle in the production of coil springs.
  • the diameter of a spring coil as well as the pitch of the spring may deviate from the corresponding nominal values due to the plastic-elastic material behavior and other influencing factors (for example tool parameters). Therefore, in the case of spring manufacturing machines too, characteristic curves are used in the control of forming operations which can later be manually corrected by the operator.
  • Coil springs or sections of coil springs are often characterized by the geometry parameters diameter and pitch. Other geometry parameters are e.g. the number of turns and the spring length.
  • the determination of characteristics is usually relatively complex for the operator. For example, the measurement of the bending angle with conventional measuring means is not easy. Sometimes, a correction or optimization of the characteristic curve (s) prescribed by the controller is dispensed with and it is instead attempted to change the control program underlying the control (eg by changing delivery values) in order to achieve the achieved molded part geometry closer to the desired desired geometry bring to.
  • the invention has for its object to provide a generic method and a generic forming machine, which are user-friendly and allow for complex molding geometries a quick set-up of the forming machine.
  • an automated characteristic curve determination operation for determining at least one actual characteristic curve is carried out prior to the productive production of (one or more) molded parts with a predetermined nominal molded part geometry.
  • the actual characteristic curve is a characteristic curve which, as a rule, can more accurately describe the infeeds required for an exact part geometry of the forming tool concerned than a characteristic curve calculated on the basis of material parameters.
  • a first shaped part section is produced by forming a first section of the workpiece.
  • the first molded part section has at least a first bend.
  • the forming tool for which the characteristic is to be determined is set to a first delivery value.
  • the delivery value may, for example, describe the position of the forming tool and / or an orientation of the forming tool relative to a suitable reference coordinate system.
  • the first delivery value may be referred to as the first delivery path; in the case of a rotationally deliverable forming tool, the first delivery value may be a delivery angle.
  • the term "bend” generally refers to a shape created by deformation other than a straight line shape, regardless of the manner in which the bend is made or produced, such as by bending, winding, or winding wire or pipe
  • a bend may be a flat bend, and it is also possible for the bend to have a torsion component (eg spring turns).
  • the geometry parameter may be, for example, a bending angle, a bending radius, a winding diameter and / or a pitch.
  • an actual characteristic curve is then determined for the selected combination of forming tool and geometry and material of the workpiece.
  • the actual characteristic curve can be derived from a previously valid characteristic curve by determining a correction value for at least one interpolation point of the characteristic curve by which an associated value of the characteristic curve must be changed in order to move from the previous characteristic curve to the new actual characteristic curve.
  • the determined actual characteristic can thus replace a previously active characteristic.
  • the generation of the actual characteristic curve can proceed in such a way that one or more correction values for the existing characteristic curve are determined and this is corrected so that it corresponds to the actual characteristic curve.
  • control of the delivery of the forming tool is carried out in a subsequent productive production of one or more moldings then using the actual characteristic.
  • the actual characteristic curve determined with the aid of an automated characteristic determination operation as a rule supplies molded parts whose actual geometry is closer to the desired nominal geometry of the molded parts than when using a characteristic curve calculated on the basis of material parameters.
  • the automated characteristic determination operation usually results in a shortening of the set-up time, a simplification of the set-up process and / or a reduction in the number of set-up parts compared to conventional approaches. Good results can be achieved systematically and independently of the operator's abilities.
  • a sufficient correction of a characteristic curve can be achieved by virtue of the fact that only a single part of the molded part (the first molded part) Section) is generated and measured by reshaping, in order to determine the actual characteristic curve or a correction value for an existing characteristic curve.
  • This may be sufficient, for example, if the existing characteristic runs between two predefined points for which the association between the delivery path and the geometry parameter is relatively well known.
  • a starting point of a characteristic may be defined so that a delivery value of 0 corresponds to a bending angle of 0 °. From this starting point, a rectilinear characteristic may extend to the end point.
  • a correction of the characteristic curve at a single interpolation point located between the starting point and the end point can already lead to a significant improvement in the later-manufactured molded part geometry.
  • At least one second automated characteristic determination operation can be carried out for optimizing the actual characteristic curve determined in the first automated characteristic determination operation.
  • An iterative improvement with two or more experiments is possible in principle. An operator may choose the number of automated characteristic determination operations such that an improvement achieved by another characteristic determination operation is no longer significant.
  • the first molded part section and the second molded part section are measured successively in a series of measuring operations by means of a measuring system, wherein first the first molded part section is generated and measured in a measuring range of the measuring system, then the first Meßformteil- section is separated from a supplied workpiece portion, and then generates the second Meßformteil section and measured in the measuring range of the measuring system.
  • a measuring system is installed on the forming machine, in the measuring range of which the shaped part sections can pass during forming.
  • the measuring range does not have to be particularly large, since it is sufficient if, in the case of a bend, the bend itself and adjacent straight line sections lie within the spatial measuring range. If a forming machine is already equipped with a measuring system, for example a camera system, this can optionally be used for the surveying operation or adapted thereto.
  • a measuring system for example a camera system
  • shaped part sections are measured optically one after the other by means of a camera.
  • a single camera may be enough.
  • a measuring mold part is produced by means of the forming machine, which has the first measuring mold part section and, associated therewith, at least one second mold section section. Thereafter, the measuring mold part is separated from a supplied workpiece section and measured by means of a measuring system.
  • the measuring mold part can have, for example, between two and ten geometrically different molded part sections, which differ from each other only in terms of the geometry parameter of interest (eg bending angle, bending radius, etc.).
  • the number of different Meßformteil- sections determines the number of possible nodes for the definition of an actual characteristic.
  • a molded part for determining a characteristic has a shape which differs in principle from the shape of those molded parts which are later set up and manufactured on the basis of the determined characteristic in the productive process. It may be a molded part optimized with respect to the characteristic curve determination, in which only a single geometry parameter (for example, bending radius, bending angle, diameter or pitch) varies stepwise between the different shaped part sections. It is also possible that the measuring molded part has a shape which corresponds to that of the molded part (individual part or series part) to be produced after completion of the device. It is also possible to design a measuring part such that e.g. Both a curve for the bending angle and for the bending radius can be created.
  • the measuring system for measuring measuring mold parts with a plurality of different mold part sections may be a measuring system associated with the forming machine but separate from the forming machine.
  • the measuring system should be able to detect at the possibly complexly deformed shaped part all Meßformteil sections which were generated in different reference forming operations, simultaneously or at least in a very short time interval and corresponding data in a suitable format to the control device of the forming machine transfer.
  • the measuring system can be a three-dimensional optical scanner system.
  • optical measuring cells with a larger number (for example three or more, in particular up to ten or more) of high-resolution digital cameras, with the aid of which complex three-dimensionally bent moldings can be precisely measured in one measuring run.
  • some or all of the interpolation points for determining an actual characteristic curve can be determined with high precision in a short time.
  • Coil springs are known components that are needed in numerous applications in large quantities and different designs. Coil springs are usually made from spring wire and designed as tension springs or compression springs or leg springs depending on the load involved in the use.
  • the spring characteristic of a helical spring can be influenced, inter alia, by that sections of different pitch or pitch gradients are designed.
  • the spring diameter can also be constant (in the case of cylindrical coil springs) or variable (for example, in the case of conical or barrel-shaped coil springs). Therefore, it is desirable to produce as accurately as possible spring diameter and pitches and / or pitch gradients and spring length and / or length of the spring sections in the production of coil springs.
  • first a first mold part section with a first diameter and a first slope and then a second mold section section with the same first diameter and a second slope are generated, which differs from the first slope.
  • the first and the second molded part section may be contiguous in the same measuring spring or in separate elements.
  • the first diameter which is identical in both parts of the molded part, to obtain a characteristic curve for the slope, ie the relationship between the delivery of a forming tool influencing the lead and the resulting lead at the first diameter
  • intermediate values for other slopes between or beyond the first and the second slope can also be determined by extrapolation and / or interpolation. Extrapolation and interpolation may be e.g. linear, polynomial or polynomial.
  • the slope can be determined not only directly but also indirectly, e.g. from the number of turns and the spring length of a spring.
  • a further increase in the reliability of characteristic curves can be achieved by additionally producing a third molded part section with a second diameter and a first pitch and a fourth molded part section with the same second diameter and a second pitch extending from the first Slope is different.
  • the second diameter differs from the first diameter.
  • first and second slopes which are generated at the different diameters, can be identical, resulting in a simplified evaluation of the measured data. However, this is not mandatory, so they may be different.
  • characteristic curves for other geometry parameters can also be determined, e.g. a characteristic for the diameter at a given slope.
  • first a first molded part section with a first pitch and a first diameter and then a second molded part section with the same first pitch and a second diameter can be generated, which differs from the first diameter.
  • the first and the second molded part section may be contiguous in the same measuring spring or in separate elements.
  • the first slope which is identical in both Meßformteil sections, to obtain a characteristic for the diameter, ie the relationship between the delivery of a diameter-influencing forming tool and the diameter thus obtained at the first Pitch.
  • intermediate values for other diameters between or beyond the first and second diameters can also be determined by extrapolation and / or interpolation.
  • Extrapolation and interpolation may be e.g. linear, polynomial or polynomial.
  • the pitch and the diameter stand here for example for certain geometric parameters of the molded part. Similarly, curves can be determined for dependencies between other first and second geometry parameters.
  • the automated characteristic determination operation comprises the steps of: generating a first mold portion having a first diameter and a first slope; Producing a second mold section having a second diameter and a second slope; Producing a third mold section having a third diameter and a third slope; and producing a fourth mold portion having a fourth diameter and a fourth pitch, each of the mold portions having a different combination of diameter and pitch.
  • the first to fourth molded part sections may be formed by different sections of one and the same molded part, which may also be referred to as a "measuring spring.”
  • a measuring spring In principle, it would also be possible to manufacture and measure the different sections of the molded part as mutually separate sections As a rule, exactly four mold part sections are sufficient for the reliable determination of a characteristic diagram, however, more than four mold section sections of different diameter and / or pitch can be generated and measured.
  • a simple evaluation to determine the characteristic curve can be carried out if at least two of the molded part sections have nominally identical diameters and different pitch and at least two of the molded part sections have identical pitch and different diameters.
  • a molded part can be produced with exactly four molded part sections, which can be described such that two of the molded part sections have nominally identical diameters and different pitches and two of the molded part sections have identical pitch and different diameters.
  • the molded parts described here with one or more molded part sections can be optimized with respect to their geometry to their task in the automated characteristic determination.
  • the molded parts have a significantly different part geometry than the molded parts to be produced during the later productive production.
  • a mold part for determining a bend angle characteristic may have two, three, four, five, six or more bends with different bend angles that cover the available bend angle range in sufficiently small increments.
  • a molded part may also be optimized for determining a bend angle characteristic by having two, three, four, five, six or more different bends with adjacent straight sections that are easy to measure due to their relatively large length.
  • helical measuring moldings with two, three, four, five, six or more spring sections of different diameters and / or different pitch are possible, in particular for the preparation of the production of coil springs.
  • the invention also relates to a forming machine configured for carrying out the method.
  • the forming machine has a forming device with one or more forming tools.
  • a retracting means for retracting an elongated workpiece, in particular a wire or tube, from a supply of material into the area of the forming means, and a cutting means for severing a finished shaped part from the elongate workpiece after completion of a forming operation ,
  • a retracting means for retracting an elongated workpiece, in particular a wire or tube, from a supply of material into the area of the forming means, and a cutting means for severing a finished shaped part from the elongate workpiece after completion of a forming operation .
  • the workpiece is cut to length prior to bending.
  • the forming machine is provided with an automated characteristic determination system configured to perform an automated characteristic determination operation of the type described in this application.
  • characteristics can be determined much faster and more accurately than heretofore and taken into account in production.
  • set-up times can be considerably shortened, so that the goal of the production can be achieved faster than previously with at least the same quality of the molded parts.
  • FIG. 1 is an oblique perspective view of a spring manufacturing machine according to one embodiment of the invention having a camera-based measurement system for use in an automated characteristic determination operation;
  • Fig. 2 shows schematically in Figs. 2A, 2B and 2C the appearances of three different mold portions with different bending angles for the determination of an actual characteristic in an automatic characteristic detecting operation;
  • Fig. 3 shows schematically in Fig. 3A a characteristic diagram for a bending operation of a bending tool, which is shown next to the diagram in Fig. 3B in a schematic axial view;
  • FIG. 4 shows schematically in FIG. 4A a characteristic diagram for a wind operation using the bending tool shown next to the diagram in FIG. 4B;
  • FIG. 5 shows schematically in Fig. 5A a characteristic diagram for a Federwindeoperation using the Windetechnikmaschines shown next to the diagram in Figure 5B.
  • Fig. 6 shows in Figs. 6A, 6B and 6C various exemplary geometries of mold parts
  • Fig. 7 shows a side view of an embodiment of a measuring molding in the form of a measuring spring for determining a characteristic curve for the production of a helical spring
  • FIG. 8 schematically shows interpolation points in a characteristic diagram, which can be determined by means of measurements on the measuring spring of FIG. 7.
  • Fig. 1 shows some structural elements of a CNC spring manufacturing machine 100 according to an embodiment of the invention.
  • the spring manufacturing machine exemplifies a forming machine and is designed as a leg spring machine to produce in a wire automated forming process a plurality of torsion springs or other by bending produced moldings nominally same desired geometry by bending and / or winding.
  • a vertically upstanding machine front wall 1 10 is constructed on a machine frame.
  • a forming device 120 with a plurality of forming tools whose positions and movements are numerically controlled via a computer numerical control device 190.
  • the forming tools of the forming device 120 and the means for holding and moving the forming tools are located in the working area of the spring manufacturing machine on the front of the machine front wall.
  • the spring manufacturing machine has on the back of the machine front wall not visible in Fig. 1, a feed rollers equipped with feed rollers, the successive wire sections coming from a wire supply and optionally guided by an optional straightening wire D with numerically controlled feed rate profile in the horizontal direction in the region of the forming device 120 can move or feed.
  • the wire is guided on the exit side through a wire guide 130 and emerges in a horizontal feed direction substantially perpendicular to the machine front wall.
  • the wire is converted to a molded article having one or more bends using numerically controlled tools of the former 120.
  • the finished molded part is separated by means of a cutting device 140 by a perpendicular to the wire feed device extending straight cut by means of a cutting tool 142 from the supplied wire.
  • the tools that can be used in forming include a bending tool 150 and a wind tool 160, the movement of which is under the control of the numerical control by means of suitable electric drives.
  • the cutting tool 142 is also used numerically controlled.
  • a possible embodiment of a leg spring machine is shown in DE 10 2007 031 514 A1, the disclosure of which is hereby made by reference to the content of this description.
  • the forming machine is provided with a camera-based optical measurement system 200 for non-contact, real-time acquisition of data about the geometry of a currently fabricated molding or portion thereof.
  • the measuring system has a CCD camera 250, which can deliver images or image sequences via an interface to a connected image processing system.
  • the image acquisition of the individual images is triggered in each case via trigger signals (trigger) of the controller.
  • the software for image processing is housed in a program module which cooperates with the control device 190 of the forming machine or is integrated in this.
  • the camera 250 is mounted such that its rectangular image field 252 (image capture area, see FIG. 2) can capture a portion of a currently fabricated molded article or a complete molded article immediately after exit from the wire guide 130 before the molded article is severed from the supplied wire.
  • a rectangular illumination device 260 is mounted, which flashes in response to triggering signals (triggers) of the control at the measuring times predetermined by the control device and enables measurement in transmitted light.
  • a reflected-light illumination device may be provided to improve the visibility of interesting details of the spring for the measurement.
  • the bending tool 150 is shown in an axial view parallel to its linear travel axis 152 in FIG. 3B.
  • the bending tool has an inner part 154 immovable in the forming operation and an outer part 156 surrounding it, which is rotatable relative to the inner part about the axis 152.
  • the inner part carries a bending mandrel 153, on the outer part of a bending pin 155 is attached, which bears against the bending mandrel opposite side of the wire D.
  • Fig. 3B shows the bending tool in its zero position, wherein the bending mandrel and the bending pin abut the sides of the wire and the wire is straight and is not loaded by the bending pin.
  • the counterclockwise rotation of the bending pin results in bending of the wire around the mandrel.
  • the angle of rotation of the bending pin starting from the zero position shown, is described by a corresponding delivery value Z, namely the angle of rotation of the bending pin.
  • a bend is generated, which can be characterized by a bending angle BW (FIG. 2).
  • the bending tool is delivered by linear displacement on the supplied and protruding from the wire guide wire until the initial position shown in Fig. 3B is reached is, in which the bending tool is in engagement with the supplied wire.
  • delivery value Z delivery value
  • a characteristic curve KL is deposited for each combination of a forming tool and the workpiece material, which was previously determined on the basis of material parameters or workpiece parameters such as strength, modulus, diameter, etc. on the basis of computational algorithms.
  • a correction value can be determined for one, a few or all characteristic points or interpolation points of the characteristic curve and taken over into the characteristic curve, so that an actual characteristic curve is improved compared to the original characteristic curve. which then serves as the basis for the control in the productive production of molded parts.
  • the forming machine is equipped with an automated characteristic determination system configured to perform an automated characteristic determination operation prior to production of molded parts having a predetermined target molding geometry to produce the above-mentioned actual characteristic or correction values for the preset characteristic.
  • the controller is programmed so that the forming machine successively manufactures a plurality of molded part sections using the bending tool 150, which are measured immediately thereafter respectively by the measuring system or the camera 250 before a molded part section is separated from the supplied wire by means of the cutting tool 142 becomes.
  • Fig. 2 shows some phases of the automatic characteristic determination operation.
  • Fig. 1 out of the wire guide 130, there protrudes a finish-bent shaped article portion 300 which, after being rotated or aligned in a vertical plane, is measured by the camera system 250 before being separated.
  • the procedure may be as follows. First of all, a measuring part is programmed, on which all bending angles are available, which are required for the creation of a characteristic as support points. Then the automated characteristic determination operation is started.
  • the wire feed first advances the wire until it has the length intended for the bending operation.
  • the bending tool 150 is brought into engagement with the wire to produce, in a first reference forming operation, a first mold portion 300-1 having a first bend B1.
  • the bending tool is set to a first delivery value, that is to say a specific angle of rotation, which according to the current characteristic curve leads to the desired bending value. angle leads.
  • the wire is not advanced during the bending operation.
  • the molded part section then has the first bend B1 lying between two straight sections ( Figure 2A).
  • This situation which is located in the field of view 252 of the camera, is measured with the camera, for which purpose the illumination device 260 briefly flashes in response to a trigger signal, in order to enable a sharp imaging of the molded part section.
  • a first actual geometry parameter in the form of the corresponding measured first bending angle is determined from the acquired image.
  • the first molded part section 300-1 is separated from the supplied wire by means of the cutting tool.
  • the delivery value of the bending tool 150 is changed to a second delivery value to produce a larger bending angle.
  • the second molded article section 300-2 shown in FIG. 2B is bent, which has a significantly larger bending angle than the first molded article section.
  • a third molded part section 300-3 is then produced with an even greater bending angle, the measurement of which then supplies in an analogous manner a third actual geometry parameter in the form of the measured third bending angle (FIG. 2C).
  • the rotational angles of the bending pin set in each case serve as known input variables, namely as the first, second, third etc. delivery value.
  • the associated measured bending angles are the dependent thereon, which allow to determine the functional relationship between the actually desired geometry parameters or bending angles and the associated delivery values.
  • the first, second, third and further delivery values here, rotation angle of the bending pin
  • the measured actual geometry parameters first, second, third etc. bending angle
  • the actual characteristic curve can be transferred to the controller by correcting the previously existing characteristic curve at the interpolation points used for the measurement by adopting calculated correction values.
  • the operator can follow the process of correction value determination on the screen and initiate the transfer by pressing a button. This completes the (first) automated characteristic determination operation.
  • the desired molded part can be moved using the thus determined actual characteristic curve or the corrected earlier characteristic curve with a virtually vanishing reject rate or a high proportion of good parts.
  • the processes are illustrated by means of a schematically illustrated characteristic diagram on the basis of FIG. 3A.
  • the bending angle reference value BW-S is plotted on the x-axis, the y-axis represents the infeed Z of the bending tool, in this case the angle of rotation of the bending pin 155 starting from its zero position.
  • the dashed straight line LIN shows a (non-realistic) linear relationship between an initial value (infeed Z and bending angle target value each 0 °) and an end point E belonging to a bending angle command value of 180 °.
  • a machine operator could manually determine a more accurate characteristic curve, for example the characteristic curve KL2 in FIG. 3A, manually, for example by means of a jig or another measuring tool, for each combination of forming tool and material.
  • the automated characteristic determination operation can significantly accelerate this characteristic determination process. The results are determined systematically accurate and reliably reproducible regardless of the skills and abilities of an operator.
  • FIGS. 4A, 4B A variant is described on the basis of FIGS. 4A, 4B, in which an arc or a bend with a defined bending radius is to be generated by means of the same bending tool 150 by a wind operation.
  • the wire is first bent around the bending mandrel without wire feed with the bending pin. Subsequently, the wire is advanced in the feed direction.
  • the bending pin urges the wire material continuously to the side, so that the arc is formed with the desired bending radius.
  • the smallest bending radius is limited due to the resulting forces.
  • the larger the bending radius (radius of curvature of the bend) to be the smaller will be the Z delivery of the bending tool, so the angle of rotation of the bending pin from its neutral position.
  • This relationship is shown in FIG. 4A on the basis of the characteristic curve KL4.
  • the nominal bending radius BR-S is plotted on the x-axis, and the y-axis represents the feed angle of the bending pin
  • the procedure for the automated characteristic determination operation is analogous to the procedure described. In this case, however, not the bending angle is determined from the camera images, but the bending radius in a bent wire section between two adjacent straight sections.
  • a separate molded part section can be made for each bending point desired as a base, then measured and finally separated from the wire before the next part of the measuring part is made.
  • Fig. 5A schematically shows a characteristic curve KL5 valid for a spring-wind operation which can be carried out by means of the wind tool 160 (Fig. 5B).
  • the wire D runs against a slope 162 of the Windewerkmaschines 160 and is thereby urged in the example down and thereby reshaped.
  • the production of a leg spring is shown, which runs out of the drawing plane or in the plane of the drawing depending on the direction of the wind.
  • the delivery of the wind tool 160 is a linear delivery.
  • the wind tool can be moved in the direction of the arrow up (diameter is larger) or down (diameter is smaller). Accordingly, on the y-axis of the Z delivery path is given in a linear dimension, on the x-axis is the setpoint DS of the spring diameter applied.
  • the determination of the characteristic can be done in an analogous manner by automated characteristic determination operation.
  • individual molded part sections can each be made, then measured and finally separated from the supplied wire before the Meßformteil- section of different geometry is made. It is also possible to form two or more shaped part sections of different geometry parameters on one and the same shaped part before it is separated from the wire. The measurement of the measuring molded part can then take place separately from the forming machine to a dedicated measuring system, which is able to determine all relevant geometry parameters in a complex time in the complex shaped mold part.
  • FIG. 6A shows a shaped measuring part 400, on which a total of nine sharp bends, each with a different bending angle BW, have been produced between adjacent straight sections by forming. This makes it possible to reliably determine a characteristic curve with nine interpolation points for the bending angle.
  • a mold part 500 is shown, which is designed to determine an actual characteristic curve for the bending radius BR.
  • a total of six arcuate bends with defined different bending radii have been produced on the shaped part, which can be measured and then used as the basis for calculating an actual characteristic curve.
  • FIG. 6C shows another measuring mold part 600, which is designed in the manner of a leg spring and has a total of six spring sections F1 to F6, each with a different spring diameter FD.
  • a spring manufacturing machine can be optimized with regard to the production of coil springs with defined diameters.
  • a molded part 700 is described, which makes it possible, in advance of the production of molded parts in the form of helical springs, to determine in an automated characteristic determination operation a plurality of characteristic curves or a characteristic map, which correlates the delivery value for a particular, the slope the spring-determining forming tool, the spring diameter and the pitch in a spring portion for different diameters and gradients represented.
  • the deformation of the spring determining forming tool can be precisely controlled.
  • the integrally formed from spring wire measuring mold 700 has exactly four merging into each other Meßformteil sections 700-1 to 700-4.
  • the first molded part section 700-1 shown on the left has a first diameter D1 which is constant over the length and a first slope S1 of the turns.
  • the immediately adjacent second molded part section has a second diameter D2, which is larger than the first diameter D1, but the same pitch S1.
  • the second molded part section 700-2 also has a constant pitch and a constant diameter over its length.
  • the second molded part section 700-2 merges into a third molded part section 700-3, which has exactly the same diameter, namely the second diameter D2, but a smaller pitch, namely a second pitch S2.
  • the third molded part section merges into a fourth molded part section 700-4, which has the same pitch as the third molded part section, namely the slope S2, but a smaller diameter D1, which corresponds to the diameter of the first Meßformteil section.
  • the first molded part section 700-1 and the fourth molded section section 700-4 thus have identical diameters, but different pitch. The same applies to the second and the third molded part section, in which case the identical diameter is larger in each case.
  • the measuring spring 700 can also be described as having two pairs of Meßformteil- sections, wherein within a pair of the Meßformteil sections each have identical pitch and different diameters. This applies in each case to the first and the second molded part section (which adjoin one another directly with the same pitch) and also to the pair of third molded part section and fourth molded part section, which likewise merge directly with one another with identical pitch.
  • the measuring spring 700 can also be described as having two pairs of Meßformteil- sections, wherein within a pair, the Meßformteil sections each having identical diameters and different pitch. This applies to both the first and the fourth molded part section (which are at the ends) and also to the pair of second molded part section and third molded part section, which merge directly with each other without changing the diameter, but with changing the pitch.
  • the characteristic field that can be determined by means of such a measuring spring takes into account a number of dependent parameters, namely the diameter and the pitch. This is particularly interesting for the subsequent production of coil springs, since there the delivery of the tools can not only depend on a slope, but also on the diameter.
  • the upwardly directed z-axis represents the infeed Z of a forming tool influencing the pitch.
  • the spring diameter D and on the other hand the slope ST is plotted.
  • the crosses represent bases of the associated map. Such a map may be helpful in accurately adjusting a pitch or diameter affecting tool for particular wires.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Bending Of Plates, Rods, And Pipes (AREA)
  • Wire Processing (AREA)

Abstract

L'invention concerne un procédé pour fabriquer des pièces formées à partir d'une pièce allongée, en particulier d'un fil ou d'un tube, par formage au moyen d'une machine de formage, selon lequel au moins une caractéristique est prédéfinie, laquelle représente une relation fonctionnelle entre un paramètre de géométrie de consigne de la pièce formée et une avance d'un outil de formage influant sur ce paramètre de géométrie, qui doit être réglée pour atteindre le paramètre de géométrie de consigne. Selon le procédé, une opération de détermination automatisée de caractéristique visant à déterminer une caractéristique réelle est réalisée avant une fabrication productive de pièces formées avec la géométrie de consigne prédéfinie. Ensuite, lors d'une fabrication productive de pièces formées, l'avance de l'outil de formage est commandée sur la base de la caractéristique réelle déterminée de façon automatisée.
PCT/EP2016/058864 2015-05-06 2016-04-21 Procédé de fabrication de pièces formées et machine de formage pour la mise en œuvre dudit procédé Ceased WO2016177582A1 (fr)

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DE102015208350.0A DE102015208350B3 (de) 2015-05-06 2015-05-06 Verfahren zur Herstellung von Formteilen und Umformmaschine zur Durchführung des Verfahrens

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WO2021048408A1 (fr) * 2019-09-12 2021-03-18 Gehring E-Tech Gmbh Procédé et dispositif pour couper à longueur et plier des éléments d'enroulement
CN114210780A (zh) * 2017-02-08 2022-03-22 米沃奇电动工具公司 形成用于卷尺的受可变应力弹簧的方法
US20230314114A1 (en) * 2017-02-08 2023-10-05 Milwaukee Electric Tool Corporation Tape Measure with Variable Preformed Stressed Spiral Spring Retraction System
CN117000920A (zh) * 2023-06-14 2023-11-07 李书云 一种弹簧机压簧辅助芯座安装结构
WO2025146373A1 (fr) * 2024-01-05 2025-07-10 ThyssenKrupp Federn und Stabilisatoren GmbH Procédé mis en œuvre par ordinateur pour régler le centre de force ou la force transversale d'un ressort hélicoïdal

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DE102016204572A1 (de) * 2016-03-18 2017-09-21 Otto Bihler Handels-Beteiligungs-Gmbh Umformmaschine und Verfahren zur Positionskorrektur des Schlittenaggregates einer solchen Umformmaschine
DE102017207612A1 (de) 2017-05-05 2018-11-08 Wafios Aktiengesellschaft Verfahren zur Herstellung eines Biegeteils und Biegemaschine zur Durchführung des Verfahrens
CN112387893A (zh) * 2020-12-23 2021-02-23 罗军 一种建筑用钢筋双头同步弯折设备
IT202200008915A1 (it) * 2022-05-03 2023-11-03 Atop Spa Sistema e metodo per il controllo di una macchina di formatura di elementi conduttori di un avvolgimento induttivo di uno statore.
DE102023201807A1 (de) * 2023-02-28 2024-08-29 Wafios Aktiengesellschaft Umformmaschine und Verfahren zur Herstellung komplex gebogener Formteile
EP4458484A1 (fr) * 2023-05-02 2024-11-06 DMG MORI Bergamo S.r.l. Procédé de cintrage et d'usinage de pièces sur une machine-outil et machine-outil pour l'usinage et le cintrage de pièces
DE102024119441A1 (de) * 2024-07-09 2026-01-15 Audi Hungaria Zrt Vorrichtung sowie Verfahren zum Betreiben einer solchen Lehren-Vorrichtung

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WO2007121985A1 (fr) * 2006-04-24 2007-11-01 Rasi Maschinenbau Gmbh Procédé de cintrage sous traction mécanique de barres, en particulier de tubes
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CN114210780A (zh) * 2017-02-08 2022-03-22 米沃奇电动工具公司 形成用于卷尺的受可变应力弹簧的方法
US20230314114A1 (en) * 2017-02-08 2023-10-05 Milwaukee Electric Tool Corporation Tape Measure with Variable Preformed Stressed Spiral Spring Retraction System
US12158338B2 (en) 2017-02-08 2024-12-03 Milwaukee Electric Tool Corporation Tape measure with variable preformed stressed spiral spring retraction system
US12429321B2 (en) 2017-02-08 2025-09-30 Milwaukee Electric Tool Corporation Tape measure with variable preformed stressed spiral spring retraction system
WO2021048408A1 (fr) * 2019-09-12 2021-03-18 Gehring E-Tech Gmbh Procédé et dispositif pour couper à longueur et plier des éléments d'enroulement
EP3987631A1 (fr) * 2019-09-12 2022-04-27 Gehring Technologies GmbH + Co. KG Procédé et dispositif pour couper à longueur et plier des éléments d'enroulement
CN117000920A (zh) * 2023-06-14 2023-11-07 李书云 一种弹簧机压簧辅助芯座安装结构
WO2025146373A1 (fr) * 2024-01-05 2025-07-10 ThyssenKrupp Federn und Stabilisatoren GmbH Procédé mis en œuvre par ordinateur pour régler le centre de force ou la force transversale d'un ressort hélicoïdal

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