Precision Machinery for Wire and Tube

Transcription

1 Precision Machinery for Wire and Tube H O S T E D B Y : CO-HO S T E D B Y : Industrie 4.0: Close Loop Quality Control for Torsion Spring Production Dr.-Ing. Uwe-Peter Weigmann October 4, 2017

2 Industrie 4.0: Close Loop Quality Control for Torsion Spring Production AGENDA Introduction: Industrie 4.0 WAFIOS iq-functions Geometrical programming with the WAFIOS Programming System WPS 3.2 EasyWay iqspring Collision control and determination of cycle time iqtoolsetup - Automatic adaption of the characteristic curve with the standard camera iqinspect Measuring and automatic correction of bending parts with an external measuring device iqbendcontrol - In-process measurement of the bending angle 2 All information and documents given are strictly confidential and must be kept secret, WAFIOS reserves the right for patent applications

3 Industrie 4.0: targets and ressources 3 All information and documents given are strictly confidential and must be kept secret, WAFIOS reserves the right for patent applications

4 Close Loop Quality Control for Torsion Spring Production AGENDA Introduction: Industrie 4.0 WAFIOS iq-functions Geometrical programming with the WAFIOS Programming System WPS 3.2 EasyWay iqspring Collision control and determination of cycle time iqtoolsetup - Automatic adaption of the characteristic curve with the standard camera iqinspect Measuring and automatic correction of bending parts with an external measuring device iqbendcontrol - In-process measurement of the bending angle 4 All information and documents given are strictly confidential and must be kept secret, WAFIOS reserves the right for patent applications

5 General description of iq-functions iq-functions are optional features for WAFIOS machines with the following benefits: iqbestspeed Reduction of set-up times iqtube2 iqbendcontrol Increased quality of the produced parts Maximizing the output rate iq-functions are available for a wide range of WAFIOS products iq-functions consist of a software application which is combined with supporting hardware if necessary, such as camera systems to control the spring length iqautopitch iqcontrol iqtoolsetup 5 All information and documents given are strictly confidential and must be kept secret, WAFIOS reserves the right for patent applications

6 Close Loop Quality Control for Torsion Spring Production AGENDA Introduction: Industrie 4.0 WAFIOS iq-functions Geometrical programming with the WAFIOS Programming System WPS 3.2 EasyWay iqspring Collision control and determination of cycle time iqtoolsetup - Automatic adaption of the characteristic curve with the standard camera iqinspect Measuring and automatic correction of bending parts with an external measuring device iqbendcontrol - In-process measurement of the bending angle 6 All information and documents given are strictly confidential and must be kept secret, WAFIOS reserves the right for patent applications

7 Production of Torsion Springs 7 All information and documents given are strictly confidential and must be kept secret, WAFIOS reserves the right for patent applications

8 Close Loop Quality Control for Torsion Spring Production AGENDA Introduction: Industrie 4.0 WAFIOS iq-functions Geometrical programming with the WAFIOS Programming System WPS 3.2 EasyWay iqspring Collision control and determination of cycle time iqtoolsetup - Automatic adaption of the characteristic curve with the standard camera iqinspect Measuring and automatic correction of bending parts with an external measuring device iqbendcontrol - In-process measurement of the bending angle 8 All information and documents given are strictly confidential and must be kept secret, WAFIOS reserves the right for patent applications

9 iqspring simulates the complete production process of the bending part iqspring Collision control and determination of cycle time Due to exact imaging of the machines, tools and work pieces, a reliable and exact collision control can be performed By simulation the complete bending process, you can determine the theoretical output before the first part is produced iqspring simulation 9 All information and documents given are strictly confidential and must be kept secret, WAFIOS reserves the right for patent applications

10 Close Loop Quality Control for Torsion Spring Production AGENDA Introduction: Industrie 4.0 WAFIOS iq-functions Geometrical programming with the WAFIOS Programming System WPS 3.2 EasyWay iqspring Collision control and determination of cycle time iqtoolsetup - Automatic adaption of the characteristic curve with the standard camera iqinspect Measuring and automatic correction of bending parts with an external measuring device iqbendcontrol - In-process measurement of the bending angle 10 All information and documents given are strictly confidential and must be kept secret, WAFIOS reserves the right for patent applications

11 Produced Value [ ] Characteristic curve Describes the plastic / elastic properties of the material Influenced by material strength, material diameter, machine and tool stiffness Need to be defined once as a function of the bending angle or coiling diameter Using methods of interpolation each single bending angle or coiling diameter don t need to be measured Using the characteristic curve the programmed bending angle or coiling diameter will be realized on the first produced part (only little deviations possible) Programmed Value [ ] without correction result of the characteristic curve 11 All information and documents given are strictly confidential and must be kept secret, WAFIOS reserves the right for patent applications

12 Close Loop Quality Control for Torsion Spring Production AGENDA Introduction: Industrie 4.0 WAFIOS iq-functions Geometrical programming with the WAFIOS Programming System WPS 3.2 EasyWay iqspring Collision control and determination of cycle time iqtoolsetup - Automatic adaption of the characteristic curve with the standard camera iqinspect Measuring and automatic correction of bending parts with an external measuring device iqbendcontrol - In-process measurement of the bending angle 12 All information and documents given are strictly confidential and must be kept secret, WAFIOS reserves the right for patent applications

13 Measuring and correcting of bending parts for the first or repeating set-up processes is currently done manually with simple measuring devices such as gauges or trial-and-error methods Challenges during the setup process Manual corrections of the bending parts during the set-up without electronic aid is time consuming and can only be done by experienced users The availability of the machine is reduced during the set-up process, which leads to increasing idle times For the manual correction of the bending parts, expensive gauges have to be manufactured for each bending part Measuring and automatic correction of bending parts with iqinspect Bending part gauge 13 All information and documents given are strictly confidential and must be kept secret, WAFIOS reserves the right for patent applications

14 Measuring and automatic correction of bending parts iqinspect allows for the automatic measuring and correction of bending parts. For that it utilizes an external measuring device to determine the geometrical deviation from the reference-geometry. The measurement data is automatically transferred from the measuring device to the machine for further calculations With the measurement data iqinspect calculates the necessary correction values and inserts them into the geometry data in the WPS 3 programming system Production The reference-geometry can be exported directly out of the WPS 3. This way no mechanical gauges are needed Correction iqinspect correction cycle 14 All information and documents given are strictly confidential and must be kept secret, WAFIOS reserves the right for patent applications Measurement manually

15 Benefits during the Set-up: Shorter set-up times through automatic transfer of measurement data from an external measuring device Less rejects in the process of setting up a bending part Simplified set-up process especially for inexperienced users Measuring and automatic correction of bending parts Avoiding of errors through automatic transfer of the measured data into the WPS 3 geometry program No expensive gauges are needed by means of the automatic export of the referencegeometry from the WPS 3 program iqinspect: comparing reference and sample part 15 All information and documents given are strictly confidential and must be kept secret, WAFIOS reserves the right for patent applications

16 Benefits during the Production: Avoiding of errors through automatic transfer of the measured data into the WPS 3 geometry program No expensive gauges are needed by means of the automatic export of the reference-geometry from the WPS 3 program No uncertainties in the quality control because of the operators' subjective evaluation Measuring and automatic correction of bending parts Recording of test and correction values Measurement of the part in the measuring device 16 All information and documents given are strictly confidential and must be kept secret, WAFIOS reserves the right for patent applications

17 Close Loop Quality Control for Torsion Spring Production AGENDA Introduction: Industrie 4.0 WAFIOS iq-functions Geometrical programming with the WAFIOS Programming System WPS 3.2 EasyWay iqspring Collision control and determination of cycle time iqtoolsetup - Automatic adaption of the characteristic curve with the standard camera iqinspect Measuring and automatic correction of bending parts with an external measuring device iqbendcontrol - In-process measurement of the bending angle 17 All information and documents given are strictly confidential and must be kept secret, WAFIOS reserves the right for patent applications

18 Conventional Way of Setting up Bending Parts Bending angles are currently measured in a subsequent process after the bending process. This requires expensive external measuring systems or gauges that have to be manufactured at high costs. The actual bending process must be completed before its quality can be evaluated. Therefore, rejects are produced until the error is detected by the operator When placing bent parts into gauges, the operators' subjective evaluation play a significant role. Therefore, uncertainties in the quality control are possible The characteristic bending curve of the tool cannot be corrected by a gauge because there is no information about the exact deviation of the bending angle 18 All information and documents given are strictly confidential and must be kept secret, WAFIOS reserves the right for patent applications

19 iqbendcontrol Functional Principle Coming soon for torsion spring machines today available for wire bending machines Patent pending Camera system with a flashlight Bending Tool with reflector plate 19 All information and documents given are strictly confidential and must be kept secret, WAFIOS reserves the right for patent applications

20 iqbendcontrol Functional Principle A reflector plate with special surface coating, mounted directly on the bending head, enables the reliable measurement of all bending angles (including ones with short bending legs) Measurment is exactly 90 to the bending plane Measurement starts when the bending pin is out of contact (measuring time only a couple of milliseconds) 20 All information and documents given are strictly confidential and must be kept secret, WAFIOS reserves the right for patent applications

21 iqbendcontrol Benefits In-process measurement of the bending angle for wire bending machines Automatic adjustment of the measured bending angles to the programmed geometry. Correction of the next bent part when the tolerance is violated. Higher and constant quality 100% measurement is possible Rejects are directly detected and can be sorted out (e.g. by connected robots or controlled sorting chute) Export of measured values and SPC possible 21 All information and documents given are strictly confidential and must be kept secret, WAFIOS reserves the right for patent applications

22 Industrie 4.0: Close Loop Quality Control for Torsion Spring Production AGENDA Introduction: Industrie 4.0 WAFIOS iq-functions Geometrical programming with the WAFIOS Programming System WPS 3.2 EasyWay iqspring Collision control and determination of cycle time iqtoolsetup - Automatic adaption of the characteristic curve with the standard camera iqinspect Measuring and automatic correction of bending parts with an external measuring device iqbendcontrol - In-process measurement of the bending angle All around geometrical programming Thank you for your attention! 22 All information and documents given are strictly confidential and must be kept secret, WAFIOS reserves the right for patent applications