Method of making brushes and brush making machine

专利摘要:
The invention is concerned with improvements in the technical field of manufacturing brushes. A brush production machine (1), which is set up to carry out a method for producing brushes, is proposed as an improvement. It is provided that a control unit (2) of the brush manufacturing machine (1) autonomously triggers a reaction depending on an input variable in order to control the brush manufacturing machine (1) at least indirectly in a defined target state.
公开号:BE1026493B1
申请号:E20195394
申请日:2019-06-19
公开日:2020-07-17
发明作者:Sebastian Morlock；Joachim Kiefer
申请人:Zahoransky Ag；
IPC主号:

专利说明:

The invention relates to a method for manufacturing brushes and a brush manufacturing machine.
For the economical production of brushes, it is necessary to achieve the highest possible technical availability of the brush manufacturing machines used and to avoid unplanned downtimes of the brush manufacturing machines.
To avoid unplanned downtimes, it is known, for example, to carry out preventive maintenance measures according to a defined plan. Even if preventive maintenance measures are carried out consistently, the brush manufacturing machines can unexpectedly get into conditions that can impair proper operation. To identify the causes and to remedy such conditions, considerable time is often required in which the brush manufacturing machines concerned are not available for production.
The object of the invention is therefore to provide a method and a brush production machine of the type mentioned at the outset with which the disadvantages outlined above can be avoided and the brush production can be made more efficient.
To solve this problem, the means and features of the independent claim directed to such a method are proposed in the method of the type mentioned. Thus, in particular to solve the problem, a method for producing brushes using a brush manufacturing machine is proposed, in which a control unit of the
Brush production machine autonomously triggers a reaction depending on an input variable in order to regulate the brush production machine at least indirectly in a defined target state.
The input variable considered by the control unit of the brush manufacturing machine can represent the previously outlined undesired conditions. As soon as the control unit detects a need for action depending on the input variable, this autonomously triggers a targeted reaction in order to regulate the brush manufacturing machine back to the defined target state. In this way, undesired states of the brush manufacturing machine can be recognized early and, above all, autonomously, and corresponding reactions can be autonomously defined and triggered by the brush manufacturing machine in order to remedy or avoid the undesired state and to regulate the brush manufacturing machine back to the defined target state. In this way, brush production can be carried out more efficiently than before. It is also possible in this way to reduce or even completely avoid unplanned downtimes or failures of the brush manufacturing machine.
It can be particularly advantageous if a variable that is autonomously defined or generated by the brush manufacturing machine is used as the input variable. The autonomously defined size can be generated, for example, by machine learning from the brush manufacturing machine and / or from the previously mentioned control unit of the brush manufacturing machine.
Furthermore, it is possible to use an actual value of a process parameter of the brush manufacturing machine and / or a variable, which can in particular be a physical variable, as the input variable.
The actual value of the process parameter and / or the size can e.g. can be determined using at least one sensor of the brush manufacturing machine.
Thus, the brush manufacturing machine can be able to autonomously monitor a process parameter of the brush manufacturing machine and / or an interesting, in particular physical, parameter and, if necessary, also initiate the necessary steps autonomously if the process parameter and / or the parameter of interest comes out of a defined tolerance range , which could lead to an impairment of the brush production or to a failure of the brush manufacturing machine without reaction.
The input variable can be stored in a memory, at least temporarily connected to the control unit, in particular the brush manufacturing machine.
The control unit of the brush manufacturing machine can access the memory in order to read out the input variable and carry out the control.
The brush manufacturing machine, in particular the control unit, can store an input variable that is defined and / or determined by the brush manufacturing machine itself in the aforementioned memory.
The control unit of the brush-making machine can also autonomously actuate at least one actuator of the brush-making machine, taking into account the input variable, as a result of which the brush-making machine is controlled in the defined desired state.
In this way, a method is created that allows a largely or even completely autonomous reaction of the brush manufacturing machine to a determined actual value and / or an input variable.
So the brush making machine that works according to the method can largely be without human
Monitoring acts in order to reduce or avoid recognizable errors, malfunctions, failure risks and the like at an early stage.
Furthermore, it can be expedient if the brush manufacturing machine, in particular the control unit of the brush manufacturing machine, autonomously defines the desired state in which the brush manufacturing machine regulates itself.
This can be done, for example, on the basis of the input variable, a predetermined production program and / or a specification transmitted to the brush manufacturing machine, in particular the control unit of the brush manufacturing machine.
It can be particularly expedient if the brush manufacturing machine, in particular the control unit of the brush manufacturing machine, learns mechanically from previously made regulations to carry out the reactions in an optimized manner.
An optimized reaction can, for example, consist in the optimized actuation of an actuator of the brush manufacturing machine, in particular the actuator mentioned above, in order to achieve the desired state as quickly as possible.
Machine learning can take place taking into account previously carried out control processes.
For this purpose, it can be advantageous if the brush manufacturing machine, in particular the control unit of the brush manufacturing machine, records the controls / regulation processes carried out and stores them in a memory, for example the memory already mentioned above.
On the basis of these regulations / regulation processes carried out in the past, the brush production machine, in particular the control unit, can learn autonomously and mechanically and adapt its behavior more quickly to new circumstances.
As an input variable for the process, e.g. a degree of wear of a wear part of the brush manufacturing machine can be used. It can be advantageous to determine the degree of wear using at least one sensor. For this purpose, this at least one sensor of the brush-making machine can be signal-connected to the control unit of the brush-making machine mentioned above. For this purpose, corresponding signal connections between the control unit and the at least one sensor and between the control unit and the at least one actuator can be present. In this way it is possible to transmit a sensor signal from the sensor to the control unit of the brush manufacturing machine. On the basis of the sensor signal, the control unit can then generate an actuating signal by which the actuator is actuated in order to bring the brush manufacturing machine into the desired state.
However, it is also possible to use a size as the input variable that represents a stock of production material that is available for production on the brush production machine. The stock of production material can be determined at least indirectly using at least one sensor of the brush manufacturing machine. In one embodiment of the method of particular importance, a drive power of the brush manufacturing machine, in particular at least one drive of the brush manufacturing machine, preferably with the aid of an actuator, can be set to a defined value as a reaction. This can happen when the input variable or a value derived from it has reached a defined limit. It can be provided here that the drive power of the brush manufacturing machine is adjusted to a value of 90% or even 80% of an output power of the actuator
Brush making machine is reduced. Of course, the drive that can be temporarily reduced in performance can also be used here as an actuator and can be controlled directly by the control unit.
For example, a wear level of a monitored wear part can also be used as an input variable. As soon as the degree of wear of the monitored wear part reaches a limit value, the drive power of the brush manufacturing machine or a drive of the brush manufacturing machine can e.g. be reduced for security reasons.
In this way, a service life of the wear part of the brush manufacturing machine can also be extended, if necessary, by reducing the power with which the brush manufacturing machine is operated. In this way, a wear-related failure of the brush manufacturing machine by induction of the drive power of the brush manufacturing machine can be delayed until e.g. either a spare part for the wear part threatened by wear is ready for replacement or a production-related standstill or a break is pending in which the wear part can be replaced and / or the brush manufacturing machine repaired without unplanned production interruption.
Furthermore, a wear degree development of a monitored wear part of the brush manufacturing machine can be compared with at least one wear degree development recorded in the past. The comparison of the degree of wear can preferably be made using the control unit of the brush manufacturing machine already mentioned. From the comparison of the degree of wear development can be unusual
Wear events can be inferred. This enables an early and preventive response to the current situation. This prevents damage to the brush making machine, the production of rejects and / or potentially dangerous situations. Furthermore, the brush production machine can carry out self-diagnosis on the basis of an unusual development of the degree of wear of at least one monitored wear part and regulate itself again by adjusting at least one process parameter to a proper state, which can correspond to the desired state. This can preferably be done entirely without human intervention. In this context, it can be advantageous if the process parameter is adapted with an actuator, for example the actuator mentioned above, which can be controlled by the control unit.
At this point it should be mentioned that process parameters are also to be understood as machine parameters, the change of which can lead to a changed behavior of the brush production machine.
In this context, it can be particularly advantageous to use the control unit to trigger a reaction if the current development of the degree of wear deviates from the recorded development of the degree of wear, which serves as a reference, to a defined extent. In response, for example, a message can be issued regarding the degree of wear. In response, a replacement part for the monitored wear part itself and autonomously can be requested from the brush manufacturing machine and / or from a PPS system (production planning and control system) connected to the brush manufacturing machine.
Furthermore, it is possible to autonomously carry out a self-diagnosis and / or error analysis as a reaction in order to identify necessary measures that should be taken in order to regulate the brush manufacturing machine back into its proper state. As already mentioned above, the brush production machine can regulate itself back to a proper state / target state, in particular with the aid of its control unit. This is done by deliberately changing at least one process parameter, in particular by actuating at least one actuator of the brush manufacturing machine, tracking the change and its effect using at least one sensor, for example using the previously mentioned sensor, and possibly making further adjustments to at least one process parameter of the brush manufacturing machine . This continues until it has returned to its proper state and / or the defined target state.
Embodiments of the method are listed below which relate in particular to the previously mentioned determination of the degree of wear of a wearing part and possible variants thereof.
Embodiment 1 of the method, wherein the degree of wear of a bundle compartment of the brush manufacturing machine is at least indirectly determined on the basis of the quality of bristle bundles divided with the bundle compartment, a measurement of the mechanical resistance when moving the bundle compartment, by means of at least one sensor and / or by means of rotary motion measurement. The quality of the divided bristle bundles can preferably be determined with a sensor, in particular with a camera and / or with an optical measuring arrangement. If an increased wear of the bundle compartment is determined, the frequency with which the
Bundle divider for removing bristle bundles from a bristle supply that is moved past this can be reduced. In this way, the bundle divider can be used longer before it actually fails due to wear. The time gained in this way can be used, for example, to procure a replacement part for the bundle compartment. The actuator controlled by the control unit can be a drive, in particular a swivel drive, of the bundle compartment. The bristle supply can be kept in a material box of the brush manufacturing machine.
Embodiment 2 of the method, in particular comprising the features of embodiment 1, the degree of wear of at least one electric drive of the brush manufacturing machine being determined at least indirectly on the basis of an operating temperature of the drive determined using a temperature sensor. A temperature sensor can be used as a sensor for this. If a critical degree of wear of the monitored drive is determined, the drive power of the drive threatened by wear can be reduced using the control unit of the brush manufacturing machine in order to delay the expected failure and to extend the service life of the drive accordingly. The drive can serve as a controlled actuator. In a third embodiment of the method it can further be provided that the pressure in a material box of the brush manufacturing machine, which is generated by bristle material and / or a material presser that presses on the bristle material, is recorded. For this purpose, the brush manufacturing machine can have at least one corresponding sensor. If a pressure that is too low is detected with the aid of the at least one sensor, the control unit of the brush production machine can cause the material presser, which acts as an actuator, to generate a higher pressure in the material box of the brush production.
In this way it is ensured that a material pressure required for the proper removal of bristle bundles from the material box of the brush manufacturing machine with the aid of a bundle divider is present in the material box.
The brush manufacturing machine operating according to the method can autonomously adjust the material pressure in the material box with the aid of its control unit.
An intervention by an operator of the brush manufacturing machine is not necessary.
It is also possible to count the number of bristles extracted from the material box with the aid of a corresponding sensor, in particular with the aid of a corresponding camera.
From the number of bristles picked up, the material pressure in the material box can be inferred indirectly.
If the control unit detects that too few bristles have been removed, it can control the material presser and cause a higher pressure in the material box via the material presser.
Embodiment 4 of the method, in particular comprising the features of the previous embodiments, the degree of wear of at least one plunger of the brush production machine being determined on the basis of an impact force with which the plunger is actuated.
A force sensor can be used as a sensor for this.
If increased wear of the plunger is measured using the sensor, the control unit of the brush manufacturing machine can reduce the frequency with which the plunger is actuated in order to extend the lifespan of the plunger until a replacement part for the plunger is available.
Embodiment 5 of the method, in particular comprising the features of the previous embodiments, the degree of wear of at least one cutting device of the brush production machine using a
preferably determined / carried out with a corresponding sensor, current consumption, vibration measurement, cutting time, knife temperature and / or cutting force is determined. If increased wear of the cutting device is detected, the brush production machine can reduce the number of cutting processes per unit of time, in particular by means of its control unit, in order to extend the expected service life of the cutting device. A drive of the cutting device can be used as the actuator, which can be controlled directly with the control unit.
Embodiment 6 of the method, in particular comprising the features of the embodiments 1 to 5, the degree of wear of at least one suction line of the brush manufacturing machine for bristle filaments being determined, in particular by measuring the volume flow and / or differential pressure. For example, a pressure sensor and / or flow sensor can be used for this purpose. The degree of wear of an intake line of the brush manufacturing machine can be caused, for example, by contamination of the intake line. If the brush production machine detects increased wear on the suction line, it can activate a cleaning device of the brush production machine, which then acts as an actuator, in order to clean the suction line. In the simplest case, the cleaning device can be or include a blower that blows a pressure surge for cleaning through the suction line.
Embodiment 7 of the method, in particular comprising the features of embodiments 1 to 6, the degree of wear of at least one grinding device of the brush manufacturing machine, in particular by camera control of a grinding tool and / or a product processed with the aid of the grinding device, on the basis of a current consumption, a particle measurement and / or on the basis of from
Dirt formation during operation of the grinding device is determined.
For this purpose, for example, a corresponding particle sensor and / or flow sensor can be used as the sensor.
In this case, a drive of the grinding device can be used as an actuator, which can be controlled directly with the control unit.
If it is foreseeable that the grinding device will fail in the foreseeable future due to increasing wear, the brush manufacturing machine, in particular the control unit of the brush manufacturing machine, can control the drive of the grinding device as an actuator in such a way that the grinding device is operated with a lower output and therefore a longer to be expected Has service life.
In this way, the impending failure can be delayed and time can be saved to procure a replacement part.
Embodiment 8 of the method, in particular comprising the features of the embodiments 1 to 7, the degree of wear of at least one milling cutter of the brush production machine being determined, in particular by camera control of the milling cutter and / or an end product processed by the milling cutter, and / or on the basis of a current consumption during operation of the milling cutter becomes.
For this purpose, for example, an optical sensor and / or a camera can be used as the sensor.
A drive of the milling cutter can be used as the actuator that the brush manufacturing machine, in particular the control unit of the brush manufacturing machine, controls in response to the degree of wear of the milling cutter.
If necessary, the drive power of the drive can also be reduced using the control unit in order to extend the expected service life of the milling cutter.
Embodiment 9 of the method, in particular comprising the features of one of the previous embodiments, the degree of wear, in particular a rupture, of a plunger tongue of the brush production machine being determined, in particular on the basis of a plunger pressure monitored during operation of the plunger tongue by means of a corresponding sensor, a pressure relief valve and / or a force measuring device . A corresponding pressure or force sensor can be used as a sensor for this purpose. A pusher drive of the pusher tongue can serve as an actuator. If, for example, a breakage of the plunger tongue is detected at least indirectly, the control unit can deactivate the plunger drive of the plunger tongue in order to avoid further damage in this way.
Embodiment 10 of the method, in particular comprising the features of one of the previous configurations, at least one physical property of the environment in which the method is carried out being taken into account by the control unit of the brush production machine as the input variable. Specifically, for example, air humidity and / or temperature in the vicinity of the brush manufacturing machine can be recorded by at least one corresponding sensor of the brush manufacturing machine and taken into account when processing bristle material. If the air humidity and / or temperature is in a range outside a tolerance range, the brush manufacturing machine, in particular the control unit, can control a heating and / or cooling and / or air conditioning device of the brush manufacturing machine as an actuator such that the air humidity and / or temperature that can be measured in the area of the brush manufacturing machine is regulated back into the tolerance range. It has been found that a certain humidity and / or temperature can be closely related to the quality of the end products produced on the brush manufacturing machine. There is also a connection between machine availability and the temperature / humidity at which the brush manufacturing machine is operated. So here too
Brush manufacturing machine taking into account a physical input variable, which, if it is outside the tolerance range, can have a negative impact on machine availability and / or production quality, autonomously influence its surroundings and regulate the brush manufacturing machine back to a desired target state by means of the control unit. Embodiment 11 of the method, in particular comprising the features of one of the previous embodiments, the input variable being a temperature and / or certain physical and / or chemical quantity of fumes extracted during filament welding from the brush manufacturing machine, in particular from its control unit, for adapting Melting temperatures are taken into account. The input variable used can be determined here by a suitable sensor of the brush manufacturing machine. A heating device of the brush production machine can be used as the actuator controlled by the control unit, with which the bristle filaments are heated for filament welding.
If an injection molding step is also used in the method, in an embodiment 12 of the method, which can include in particular the features of one of the previous embodiments, an injection pressure during injection molding can be taken into account as an input variable by the brush manufacturing machine, in particular by its control unit. The spray pressure can be determined using an appropriate sensor on the brush manufacturing machine. An injection molding machine of the brush manufacturing machine can be used as the controlled actuator, which can be influenced by means of the control unit of the brush manufacturing machine. If it is determined that the spray pressure is too low, it fits
Brush manufacturing machine the spray pressure accordingly. For this purpose, the control unit can transmit a corresponding control or regulating signal to the injection molding machine.
Embodiment 13 of the method, in particular comprising the features of one of the previous embodiments, the degree of wear of at least one screw-in servomotor of the brush production machine being determined, in particular on the basis of a temperature measurement, resistance monitoring, vibration measurement, monitoring of rotational speeds, torque measurement, a count of windings generated using the screw-in servo motor. For this purpose, for example, a corresponding resistance sensor, temperature sensor, strain sensor, vibration sensor and / or optical sensor and / or a camera can be used as the sensor. In this control circuit, the screw-in servomotor can be controlled as an actuator by the control unit.
Embodiment 14 of the method, in particular comprising the features of one of the previous embodiments, the degree of wear of at least one ram of the brush-making machine being determined with a sensor, in particular with a pressure sensor, with a pressure relief valve and / or with a force sensor. For this purpose, a corresponding pressure sensor and / or a force sensor can be used as the sensor, for example. The pressure determined with the sensor or the force determined with the sensor can serve as an input variable and can be taken into account by the brush production machine, in particular its control unit. A pusher drive of the pusher tongue can be controlled as an actuator. In response to detected, critical wear, the pusher drive can be controlled accordingly by the control unit in order to extend the service life of the pusher tongue,
until a replacement part is available for the jack tongue. Embodiment 15 of the method, in particular comprising the features of one of the previous embodiments, the degree of wear of at least one drill of the brush production machine being determined, in particular on the basis of a drilling feed measurement, a torque recording on a drill chuck of the drill and / or on the basis of a rotational speed of the drill. A determined torque and / or a rotational speed of the drill can serve as an input variable. For example, a speed sensor, a torque sensor, a force sensor and / or a displacement sensor can be used as the sensor. In this control circuit, a drive of the drill can serve as a possible actuator, which in turn is controlled accordingly in order to bring the brush manufacturing machine into the desired target state. Embodiment 16 of the method, in particular comprising the features of one of the previous embodiments, the degree of wear of at least one pin pack of the brush manufacturing machine being determined, preferably on the basis of a particle development when using the pin pack with the aid of a camera and / or on the basis of a pressing-in pressure that occurs when in use of the pen package. For this purpose, for example, a corresponding optical sensor and / or a pressure or force sensor and / or a camera can be used as the sensor for determining an input variable. A drive of the pin package can be used as a possible actuator in this control circuit, which drive is in turn regulated accordingly in order to bring the brush production machine into the desired target state.
Embodiment 17 of the method, in particular comprising the
Features of one of the previous refinements, the degree of wear of at least one, in particular variable, circular arc notch of the brush production machine being determined, in particular indirectly by counting bristle filaments of a bristle bundle made up of a set of loose bristle filaments with the aid of the, in particular variable, circular arc notch. For this purpose, a corresponding optical sensor and / or a camera, for example, can be used as a sensor for determining an input variable for the control. An actuator of the variable circular arc notch can be controlled as a possible actuator in this control loop. In this example, the control unit can use a number of bristle filaments in a bristle bundle as the input variable for the control. Embodiment 18 of the method, in particular comprising the features of one of the previous embodiments, the degree of wear of a wire pulling device of the brush manufacturing machine being determined, in particular by preferably optically checking a wire drawn off with the wire pulling device. For this purpose, for example, a corresponding optical sensor and / or a camera can be used as a sensor for determining an input variable. A drive of the wire draw-off device can be controlled as a possible actuator in this control circuit.
Embodiment 19 of the method, in particular comprising the features of one of the previous embodiments, the degree of wear of at least one wire cutting device of the brush manufacturing machine being determined, in particular on the basis of a current consumption during operation of the wire cutting device, a vibration measurement, a feed-time diagram and / or a cutting time . For this purpose, a sensor for determining a
Input variable for the control, for example, a vibration sensor can be used. A drive of the wire cutting device can be controlled as a possible actuator in this control circuit.
Embodiment 20 of the method, in particular comprising the features of one of the previous embodiments, the degree of wear of at least one filament cutting device of the brush production machine being determined, in particular on the basis of a current consumption and / or vibration measurement during operation of the filament cutting device. For this purpose, for example, a vibration sensor or a current measuring device can be used as a sensor for determining an input variable. A drive of the filament cutting device can be controlled, for example, as a possible actuator in this control circuit. Embodiment 21 of the method, in particular comprising the features of one of the previous configurations, the degree of wear of at least one tamping tool of the brush manufacturing machine being determined, in particular by preferably optically checking bristle bundles tamped with the tamping tool. For this purpose, for example, a corresponding optical sensor and / or a camera can be used as a sensor for determining an input variable. A drive of the tamping tool, for example, can be controlled as a possible actuator in this control circuit. Embodiment 22 of the method, in particular comprising the features of one of the previous embodiments, the degree of wear of at least one wire feed device of the brush production machine being determined. For this can be used as a sensor
Determining an input variable, for example a corresponding optical sensor and / or a camera and / or a rotary encoder can be used. A drive of the wire feed device can be controlled, for example, as a possible actuator in this control circuit.
Embodiment 23 of the method, in particular comprising the features of one of the previous configurations, the degree of wear of at least one clamping insert of the brush manufacturing machine being determined for a wire to be screwed in, preferably by means of voltage measurement and / or by means of vibration measurement and / or by means of temperature measurement on a linear motor. For this purpose, a corresponding optical sensor, a temperature sensor, a measuring circuit, a voltage measuring device and / or a camera can be used as a sensor for determining an input size. As a possible actuator in this control circuit, for example, a drive of the clamping insert can be controlled.
Embodiment 24 of the method, in particular comprising the features of one of the previous embodiments, the degree of wear of a bending device of the brush manufacturing machine for bending a stick wire, for example a screwed-in brush, being determined, in particular by measuring a current consumption of a servo motor and / or by means of a wire feed measurement . For this purpose, an optical sensor, a temperature sensor, a measuring circuit, a voltage measuring device and / or a camera can be used as a sensor for determining an input variable. A drive of the bending device can be controlled, for example, as a possible actuator in this control circuit.
Embodiment 25 of the method, in particular comprising the
Features of one of the previous refinements, the degree of wear of a wire stretching device of the brush manufacturing machine being determined, in particular by measuring a current consumption during operation of the wire stretching device and / or using a distance measurement, a force measurement, particularly preferably using a tensile force measurement. For this purpose, a corresponding optical sensor, a temperature sensor, a measuring circuit, a displacement sensor, a current measuring device and / or a camera can be used as a sensor for determining an input variable. A drive of the wire stretching device can be controlled, for example, as a possible actuator in this control circuit.
Embodiment 26 of the method, in particular comprising the features of one of the previous embodiments, the degree of wear of at least one puck handling hose of the brush manufacturing machine being determined, in particular by differential pressure measurement, by means of vacuum measurement and / or volume flow measurement. For this purpose, a corresponding pressure sensor and / or volume flow sensor and / or a camera can be used as a sensor for determining an input variable for the control. For example, a suction device of the brush manufacturing machine can be controlled as a possible actuator in this control circuit.
Embodiment 27 of the method, in particular comprising the features of one of the previous embodiments, the degree of wear of a wire cutting device, in particular for a flat wire for producing bundle anchors and / or for a round wire for producing loops, being determined, in particular by measuring a cutting force and / or by measuring or determining a geometry of the cut wire. For this purpose, an optical sensor, a force or pressure sensor and / or a camera, for example, can be used as a sensor for determining an input variable. A drive of the wire cutting device can be controlled as a possible actuator in this control circuit. Furthermore, the inventory of production material that is available on the at least one brush production machine can be monitored at least indirectly with the aid of a sensor, in particular with the aid of the previously mentioned, and taken into account as an input variable. The sensor can be set up to determine an input variable, which can also be referred to as a parameter, which represents the inventory of production material and can thus at least indirectly infer the current inventory.
Further configurations of the previously mentioned method are listed below, which are primarily concerned with variants of the previously mentioned inventory monitoring: embodiment 28 of the method, in particular comprising the features of one of the previous configurations, the input quantity being the stock of bristle material in a material box of the brush production machine is monitored in the material box with the aid of a corresponding sensor, in particular with the aid of a pressure sensor. In response to a decreasing inventory, the brush manufacturing machine can trigger an autonomous reordering of bristle material, in particular via its control unit. For this, the control unit can e.g. Submit or transfer a corresponding order message to or via a PPS system.
Embodiment 29 of the method, in particular comprising the
Features of one of the previous embodiments, wherein the stock of bristle material contained in a filament strand for the production of brushes is determined and taken into account as an input variable, in particular by measuring the filament strand length by means of at least one corresponding sensor or displacement sensor. Here, too, a drop in the stock below a critical value can cause the control unit of the brush manufacturing machine to autonomously order replenishment of the required material and / or to reduce a production rate. With the aim of being able to produce with the existing stock until a planned standstill of the brush manufacturing machine is pending and / or supplies of material have been delivered to the brush manufacturing machine. In this way, an unplanned production downtime can be prevented.
To achieve the object, a brush manufacturing machine with the means and features of the independent claim directed to a brush manufacturing machine is also proposed. Thus, in particular to solve the problem, a brush production machine is proposed which is set up to carry out the method described in detail above and claimed in the corresponding claims. For this purpose, the brush manufacturing machine can have a control unit, at least one sensor and / or at least one actuator. The sensor and the actuator can be connected to the control unit of the brush manufacturing machine via signal connections. In this way, data, information, measured values or the like acquired by the sensor can be made available to the control unit for the control. Via the signaling connection between the
Control unit and the actuator, the control unit can transmit control and / or control signals to the at least one actuator of the brush manufacturing machine. The sensor is preferably set up to determine an actual value of at least one process parameter of the brush manufacturing machine that can be influenced by the actuator as an input variable for the control unit. The sensor can be set up to determine an actual value of a variable of interest, in particular a physical variable, as an input variable, which can be taken into account by the control unit. The control unit can be set up to operate the actuator autonomously. The aim is to regulate the brush manufacturing machine in a defined target state. Furthermore, the brush manufacturing machine, in particular a control unit of the brush manufacturing machine, can be set up for the autonomous generation of an input variable. Particularly in the case of such a brush manufacturing machine, which is equipped with artificial intelligence and / or is set up for machine learning, the brush manufacturing machine can itself define an input size that can be made available to the control unit of the brush manufacturing machine for the desired autonomous control of the brush manufacturing machine. In this way, a brush manufacturing machine can be created that is self-learning and can trigger defined reactions based on experience in order to automatically and autonomously bring itself back to the defined target state as quickly and efficiently as possible if deviations from a defined target state of the brush manufacturing machine are found. In this way, incorrect productions, rejects and the like can be avoided and the production of brushes can be made more efficient.
An input considered by the brush making machine
Gear size can be a degree of wear of a wearing part.
Furthermore, the brush manufacturing machine can have at least one sensor, for example the sensor already mentioned above, which is set up to determine the degree of wear of a wearing part of the brush manufacturing machine.
In this way, a brush production machine is created which, taking into account the degree of wear of at least one wear part, is able to trigger reactions autonomously.
This can be done by actuating the previously mentioned actuator of the brush manufacturing machine.
The aim of the autonomously triggered reactions can, for example, be to extend the service life of the brush manufacturing machine in such a way that the brush manufacturing machine can continue to be operated with reduced power, for example, until a planned maintenance interval is due and / or a spare part for the monitored wear part is available for replacement.
It can also be advantageous if the brush production machine has at least one actuator, for example the one already mentioned above, by means of which the control unit is set up to change a process parameter and / or a setting of the brush production machine in order to regulate the brush production machine in the desired state .
In one embodiment of the brush manufacturing machine, the control unit, in particular by means of one or the actuator, can be set up to change, in particular to reduce, a drive power of the brush manufacturing machine.
This with the aim of regulating the brush manufacturing machine in the desired state.
It should be noted here that the target state can of course vary depending on the particular situation in which the brush manufacturing machine is located.
If, for example, excessive wear of a safety-relevant wearing part is detected by the brush manufacturing machine, it may be advantageous or necessary for safety reasons to reduce the drive power of the brush manufacturing machine, e.g. to 90% or 80% of an output power of the brush making machine. In this way, damage to the brush manufacturing machine due to failure of the wear part threatened by wear can be avoided. In addition, the service life of the brush manufacturing machine, especially the wearing part, can be extended if necessary by reducing the drive power. In this way it can be avoided that an unplanned production failure occurs. This is particularly relevant in the case of a linked production of brushes in which several brush manufacturing machines are linked to one another in terms of production technology. Here, the total availability of the linked production plant can result, for example, from the product of the technical availability of the linked individual machines, so that it is of great importance for a high overall availability to optimize the individual availability.
The brush manufacturing machine can have, for example, a vibration sensor, a force sensor, a pressure sensor, a volume flow sensor, a temperature sensor, an optical sensor, a measuring circuit and / or a camera as at least one sensor.
All data, values, states and / or sizes that can be determined with the at least one sensor can be used by the brush manufacturing machine and also as part of the method as input size (s) and taken into account by the control unit.
The following are configurations of those described above
Brush production machine explained in more detail, which deal primarily with variants of the at least one sensor for determining an input variable, which represents a degree of wear of a wear part of the brush production machine. Of course, all of the objective features mentioned and explained in connection with the method described in detail above are suitable for forming further configurations of the brush manufacturing machine in combination with the features of the brush manufacturing machine set out in the claims. In this respect, the invention is not limited to the combinations of features contained in the claims.
Embodiment 1, wherein the at least one sensor is set up to determine the degree of wear of at least one bundle compartment of the brush manufacturing machine. The degree of wear serves as an input variable. For example, a camera can be used as a sensor, with which the quality of bristle bundles divided off with the bundle divider can preferably be continuously monitored.
Embodiment 2, in particular comprising the features of embodiment 1, the at least one sensor being a temperature sensor for measuring the temperature of at least one electric drive of the brush manufacturing machine.
Embodiment 3, in particular comprising the features of one of the previous embodiments, the at least one sensor being a force sensor for monitoring a cutting force of a cutting device and / or a sensor and / or a camera for monitoring a geometry of a wire cut with the cutting device.
Embodiment 4, in particular comprising the features of one of the previous embodiments, the at least one sensor being a force sensor for monitoring an impact force of a plunger of the brush manufacturing machine. This is preferably with the aim of continuously monitoring a degree of wear of the ram. There may be a connection between the increasing degree of wear of the ram and the increasing impact force. Embodiment 5, in particular comprising the features of one of the previous embodiments, the at least one sensor being a sensor for at least indirectly determining the degree of wear of a filament cutting device of the brush manufacturing machine. For example, a force and / or pressure sensor can function as a sensor for determining an input variable. Embodiment 6, in particular comprising the features of one of the previous embodiments, the at least one sensor being a sensor for determining a degree of wear of at least one suction hose of the brush manufacturing machine for bristle filaments, in particular a volume flow sensor and / or a pressure sensor.
Embodiment 7, in particular comprising the features of one of the previous embodiments, the at least one sensor being a sensor, in particular a camera and / or an optical sensor, for at least indirectly determining the degree of wear of a grinding device of the brush production machine. Embodiment 8, in particular comprising the features of one of the previous embodiments, wherein the at least one sensor is a sensor for at least indirectly determining the degree of wear of a milling cutter of the brush manufacturing machine, in particular a camera and / or a sensor for determining a current consumption during operation of the milling cutter, for example Current measuring device or a current measuring circuit.
Embodiment 9, in particular comprising the features of one of the previous embodiments, the at least one sensor being a sensor for at least indirectly determining the degree of wear of a screw-in servo motor, in particular a temperature sensor, a resistance sensor, a speed sensor, a vibration sensor and / or a torque sensor and / or a device for counting turns which are generated when a wire is screwed in.
Embodiment 10, in particular comprising the features of one of the previous embodiments, the at least one sensor being a sensor for at least indirectly determining the degree of wear of at least one ram tongue of the brush manufacturing machine, in particular a pressure sensor and / or a force sensor and / or a pressure relief valve.
Embodiment 11, in particular comprising the features of one of the previous configurations, the at least one sensor being a sensor for at least indirectly determining the degree of wear of a drill of the brush manufacturing machine, in particular a sensor for measuring a drilling feed, a torque sensor on a drill chuck of the drill and / or a speed sensor.
Embodiment 12, in particular comprising the features of one of the previous embodiments, the at least one sensor being a sensor for at least indirectly determining the degree of wear of at least one pin pack of the brush manufacturing machine, in particular a camera, a pressure sensor and / or an optical one
Sensor, preferably for determining particle development when using the pen package.
Embodiment 13, in particular comprising the features of one of the previous embodiments, the at least one sensor being a sensor for at least indirectly determining the degree of wear of an, in particular variable, circular arc notch of a bundle compartment device of the brush manufacturing machine, in particular with which a count of bundles combined using the circular arc notch is bundled Bristle filament is possible.
Embodiment 14, in particular comprising the features of one of the previous embodiments, the at least one sensor being a sensor for at least indirectly determining the degree of wear of a wire pulling device of the brush manufacturing machine, in particular with which a wire pulled off with the wire pulling device can be checked in terms of its thickness, width, hardness, corrugation is.
Embodiment 15, in particular comprising the features of one of the previous embodiments, the at least one sensor being a sensor for at least indirectly determining the degree of wear of a wire cutting device of the brush manufacturing machine, in particular with which a vibration measurement can be carried out, a current consumption during operation of the wire cutting device is measurable and / or a feed -Time diagram and / or a cutting time can be determined.
Embodiment 16, in particular comprising the features of one of the previous embodiments, the at least one sensor being a sensor for at least indirectly determining the degree of wear of a filament cutting device of the brush manufacturing machine, in particular with which a current consumption measurement and / or a vibration measurement can / can be carried out during operation of the filament cutting device.
Embodiment 17, in particular comprising the features of one of the previous embodiments, wherein the at least one sensor is a sensor for at least indirectly determining the degree of wear of at least one tamping tool of the brush manufacturing machine, preferably a camera, with which the quality of bristle bundles tamped with the tamping tool can be checked. Embodiment 18, in particular comprising the features of one of the previous configurations, the at least one sensor being a sensor for determining the degree of wear of a wire feed device of the brush manufacturing machine, in particular a camera and / or a rotary encoder. Embodiment 19, in particular comprising the features of one of the previous embodiments, the at least one sensor being a sensor for at least indirectly determining the degree of wear of at least one clamping insert of the brush manufacturing machine, with which a wire can be held when screwing in, in particular the sensor for carrying out a voltage measurement is set up on a linear motor with which the clamping insert is moved, and / or comprises or is a camera. Embodiment 20, in particular comprising the features of one of the previous embodiments, the at least one sensor being a sensor for at least indirectly determining the degree of wear of a bending device of the brush manufacturing machine for bending a wire, in particular for V-bending a stick wire of a brush to be produced, in particular for measuring a current consumption on the servo motor and / or for measuring a feed is set up.
The sensor can, for example, be a displacement sensor or comprise a current measuring device and / or a camera.
Embodiment 21, in particular comprising the features of one of the previous embodiments, wherein the at least one sensor is a sensor for at least indirectly determining the degree of wear of a wire stretching device of the brush manufacturing machine, in particular with which a current consumption measurement, a path measurement (path sensor) and / or a measurement of tensile forces ( Force and / or pressure sensor) can be measured during operation of the wire stretching device.
Design 22, in particular comprising the features of one of the previous designs, wherein the at least one sensor is a sensor for at least indirectly determining the degree of wear of at least one puck handling hose of the brush manufacturing machine, in particular a suction hose, in particular a pressure sensor and / or a volume flow sensor and / or an optical sensor, and / or a camera.
Embodiment 23, in particular comprising the features of one of the previous embodiments, the at least one sensor being a sensor for at least indirectly determining the degree of wear of a wire cutting device of the brush manufacturing machine, in particular for a flat wire for the manufacture of bundle anchors and / or for a round wire for the manufacture of loops , in particular a cutting force sensor, and / or for measuring a geometry of a cut wire.
The brush manufacturing machine can also be set up to
monitor a stock of production material available to the brush making machine for making brushes. For this purpose, the brush manufacturing machine can have at least one corresponding sensor, at least one corresponding measuring device and / or at least one camera. A variable determined by the sensor, which is related to the inventory of production material, can be taken into account by the control unit as an input variable. Furthermore, it should be noted that in the context of the claimed technical teaching, production material is to be understood as any material that is required or used in the manufacture of brushes for operating the brush production machine. Production material in the context of the claimed technical teaching is also understood to be material that becomes part of the products to be manufactured.
Embodiments of the brush production machine are described below, which relate to variants of the at least one sensor for monitoring the inventory of production material: Embodiment 24, in particular comprising the features of one of the previous configurations, wherein the at least one sensor for monitoring the inventory of bristle material is set up in a material box of the brush manufacturing machine is, in particular wherein the at least one sensor is a pressure sensor.
Embodiment 25, in particular comprising the features of one of the previous embodiments, the at least one sensor for monitoring the stock of bristle material in a filament rod being set up, which can be processed with the brush production machine, in particular the sensor for determining a remaining length of a filament strand is set up.
The invention will now be described in more detail using exemplary embodiments, but is not restricted to these exemplary embodiments. Further exemplary embodiments result from a combination of the features of individual or a plurality of protection claims with one another and / or in a combination of individual or more features from the general description and / or the exemplary embodiments. They show in a partially highly schematic representation: FIG. 1: A flow chart to illustrate a first variant of the method according to the invention.
Figure 2: Another flow chart to illustrate a further variant of the method according to the invention.
Figure 3: A schematic representation of a brush manufacturing machine set up to carry out the method.
Figure 4: A control loop used in the implementation of the method, which comprises a control unit, a sensor and an actuator of the brush manufacturing machine.
In the following description of various embodiments of the invention, elements that correspond in terms of their function receive corresponding reference numbers even with a different design or shape. All of the figures show at least parts of a brush manufacturing machine, designated as a whole by 1. The brush manufacturing machine 1 comprises a control unit 2, at least one sensor 3 and at least one actuator 4. The control unit 2 is designed to operate the actuator 4 autonomously in order to control the brush manufacturing machine 1 in a defined desired state.
The autonomous actuation of the actuator 4 is optionally also taking into account an input variable, which can be determined, for example, with the aforementioned sensor 3.
The input variable can represent certain process parameters relevant to the production of brushes and / or situation-dependent influencing factors that are autonomously analyzed by the control unit 2 of the brush manufacturing machine 1.
If the brush manufacturing machine 1, in particular its control unit 2, detects a need for action, the reaction is triggered.
Both the sensor 3 and the actuator 4 are connected to the control unit 2 of the brush manufacturing machine 1 via signal connections 2b.
In this way it is possible to transmit an input variable determined by the sensor 3 to the control unit 2.
After analysis of the input variable, the control unit 2 can, if a need for action has been identified, actuate the actuator 4 accordingly via the signaling connection in order to regulate the brush manufacturing machine 1 in the desired target state.
The sensor 3 is set up to determine an actual value of an in particular physical quantity and / or an actual value of a process parameter of the brush manufacturing machine 1 as the input variable for the control.
For this purpose, in particular those input variables come into consideration which are related to a process parameter of the brush manufacturing machine 1, which in turn can be influenced by the at least one actuator 4.
Different sizes and parameters that can be used at least indirectly as input values are explained in more detail in the general part of the description.
The brush manufacturing machine 1 also has a memory 2a, to which the control unit 2 of the brush manufacturing machine 1 has access.
Preset input variables for the controls, which are determined by the brush manufacturing machine 1 itself and also defined by the brush manufacturing machine 1 or its control unit 2, can be stored in this memory 2a.
The control unit 2 can read the input variables from their access to the memory 2a and use them for an analysis and as a basis for an autonomous control.
The brush manufacturing machine 1 or its control unit 2 are also set up for the autonomous generation of an input variable for the control of the brush manufacturing machine 1 and its actuators 4.
Furthermore, the brush manufacturing machine 1 is set up by its control unit 2 for machine learning.
Based on past regulations, the brush manufacturing machine 1 can independently generate optimized reaction patterns in order to optimize the regulation of the brush manufacturing machine 1 in the desired state.
The input variable taken into account by the brush manufacturing machine 1 can be, for example, a degree of wear of a wearing part 5, 6 of the brush manufacturing machine 1.
Different wear parts 5, the degree of wear of which can be taken into account when carrying out the method by the brush manufacturing machine 1 and its control unit 2, are explained in detail in the general part of the description.
The sensor or sensors 3 of the brush manufacturing machine 1 are then set up to determine the degree of wear of the monitored wear part 5.
It can be done directly through observation and / or
Measurement of the respective wear part 5 take place or directly on the basis of a size related to the degree of wear of the wear part 5.
For example, a production result in which the observed wear part 5 is involved can be monitored and checked or evaluated.
Based on a deteriorating result, the degree of wear of the wear part 5 can be deduced.
The result of this test can thus be taken into account by the control unit 2 as an input variable for the autonomous control of the brush manufacturing machine 1.
The previously mentioned at least one actuator 4 of the brush manufacturing machine 1 is set up to change a process parameter and / or a setting of the brush manufacturing machine 1 in such a way that the brush manufacturing machine 1 is regulated in the desired state.
In the exemplary embodiment of a brush manufacturing machine 1 shown in FIGS. 3 and 4, a monitored wear part 5 is a bundle remover 6 of the brush manufacturing machine 1. With the bundle remover 6, bristle bundles from a material box 7 of the brush manufacturing machine 1 are gripped and transferred to a stuffing tool 8 of the brush manufacturing machine 1.
With the aid of the tamping tool 8, the bristle bundles are successively stuffed into a brush body 9 of a brush to be produced.
For this purpose, the brush body 9 is clamped on a holding device 10 of the brush manufacturing machine 1.
If it is determined with the aid of a sensor 3 of the brush production machine 1 that the bristle bundles which are covered with the bundle divider © are no longer of the required quality, this can be attributed to an increasing degree of wear of the bundle collector 6. If the quality of the bristle bundles allows the further production of brushes, the actuator 4, here a drive 11 of the bundle collector 6, can be controlled using the control unit 2 in such a way that a drive power of the drive 11 is reduced. This can mean that the bundle pickup 6 is moved at a lower speed. The result is that the cycle time is extended or a number of bristle bundles per unit time decreases. In this way, the expected service life of the bundle collector 6 can be extended.
Depending on the application, different sensors can be used as sensors 3. For example, it is conceivable that the brush manufacturing machine 1 has at least one sensor 3, a vibration sensor, a force sensor, a pressure sensor 12, a volume flow sensor, a temperature sensor, an optical sensor, a measuring circuit and / or a camera 16. A further control loop can be explained on the basis of the exemplary embodiment of the brush production machine 1 shown in FIGS. 3 and 4. This control circuit comprises, as sensors 3, a plurality of pressure sensors 12 distributed in or on the material box 7 of the brush manufacturing machine 1. These pressure sensors 12 record the material pressure transmitted to the bristle filaments 13 located in the material box 7. The material pressure, which acts on the pressure sensors 12 of the brush manufacturing machine 1 via the bristle filaments 13, is generated by material pressers 14. The pressure values determined by the pressure sensors 12 are provided to the control unit 2 of the brush manufacturing machine 1 as an input variable. If the material pressure, which is recorded with the pressure sensors 12, drops below a critical value, the control unit 2, by means of a corresponding control or control signal, causes the material pushers 14 to increase the pressure acting on the bristle filaments 13 in order to increase the material pressure in the material box 7 in to bring a target range. The material pressure caused by the material presser 14 in the material box 7 on the bristle filaments 13 in the material box 7 ensures that the bristle filaments 13 are pressed against the bundle collector 6. A correct material pressure in the material box 7 is relevant for uniform gripping of bristle bundles with the bundle remover 6.
For grasping bristle bundles, the bundle pickup 6 has a compartment notch 15 into which the bristle filaments 12 are pressed due to the material pressure when the bundle pickup 6 moves past the material box 7. If the material pressure is too low, bristle bundles are included that contain too few bristle filaments 13. In the exemplary embodiment of the brush production machine 1 shown in FIG. 3, a check is carried out to determine whether the bristle bundles comprised have a sufficient number of bristle filaments 13 using a sensor 3 in the form of a camera 16. The camera 16 can be used to determine the number of bristle filaments 13 combined in a bristle bundle . The determined number of bristle filaments 13 in a bristle bundle is compared by the control unit 2 of the brush manufacturing machine 1 with a target value. If this comparison shows that too many bristle filaments 13 have been combined in a bristle bundle, the pressure that the material pressers 14 exert on the bristle filaments 13 in the material box 7 of the brush manufacturing machine 1 can be reduced by a corresponding control signal from the control unit 2 to the material pressers 14. If, when checking the bristle bundles using camera 16 as sensor 3, it is determined that the number of bristle filaments 13 in a stuffed bristle bundle is too small, the
Gel unit 2 of the brush manufacturing machine 1 autonomously a regulating or control signal, which is transmitted to the material presser 14 and causes it to increase the material pressure on the bristle filaments 13 in the material box 7 of the brush manufacturing machine 1.
The brush manufacturing machine 1 is thus set up to carry out the method described below. The control unit 2 of the brush manufacturing machine 1 autonomously triggers a reaction depending on an input variable in order to control the brush manufacturing machine 1 at least indirectly in a defined target state. A variable that is generated by the brush manufacturing machine 1, in particular through machine learning, autonomously defined or generated, can be used as the input variable. However, it is also possible to use an actual value of a physical variable as the input variable. The actual value of the physical quantity is determined with the aid of at least one sensor 3, 12, 16 of the brush manufacturing machine 1. The physical quantity is related to a process parameter of the brush manufacturing machine 1, which in turn can be influenced by an actuator 4, 11, 14 of the brush manufacturing machine 1. The control unit 2 of the brush manufacturing machine 1 then actuates at least one actuator 4, 11, 14 of the brush manufacturing machine 1, taking into account the input variable in response to a determined deviation from a desired state. The targeted and autonomous actuation of the actuator 4, 11, 14 of the brush manufacturing machine 1 the brush manufacturing machine 1 is regulated in the defined target state.
The brush manufacturing machine 1 is set up, in particular by its control unit 2, to learn mechanically from controls made in the past. As a result, the control unit 2 carries out the reactions in a targeted and optimized manner and, for example, actuates the actuator 4, 11, 14 in an optimized manner in order to bring about the desired state as quickly as possible.
In one embodiment of the method, for the execution of which the brush manufacturing machine 1 at least partially shown in the figures is also set up, a degree of wear of a wearing part 5, 6 of the brush manufacturing machine 1 is used as a further input variable. The degree of wear can be determined at least indirectly using at least one sensor 3, 12, 16. In a further embodiment of the method, for the implementation of which the brush manufacturing machine 1 is also set up, a size is used as the input variable which represents a stock of production material, here for example a stock of bristle filaments 13 in the material box 7 of the brush manufacturing machine 1. The stock can be determined at least indirectly using at least one sensor 3, 12, 16 of the brush manufacturing machine. When monitoring the inventory of the material box 7, the previously mentioned pressure sensors 12 can be used, which are distributed on the material box 7 of the brush manufacturing machine 1. In response to a decreasing stock of bristle filaments 13 in the material box 7 of the brush manufacturing machine 1, the control unit 2 of the brush manufacturing machine 1 can autonomously reorder a supply of bristle filaments 13 and / or, if necessary, extend the cycle time and thus reduce the production rate. This is with the aim of avoiding an unplanned downtime of the brush manufacturing machine 1 and at least being able to continue producing at a reduced production rate. Furthermore, the brush manufacturing machine 1 can use its control unit 2 and at least one corresponding actuator 4, 11 to set a drive power of the brush manufacturing machine 1 to a defined value, for example to a value of 90% or 80% of an output power. This is particularly the case when a degree of wear of a monitored wear part 5, e.g. of the bundle collector 6 has reached a defined limit. In this way, the service life of the monitored wear part 5, here the bundle remover 6, can be extended. Furthermore, further damage to the brush manufacturing machine 1 can be avoided or reduced in the same way as a potential accident or injury risk for an operator of the brush manufacturing machine 1.
The brush manufacturing machine 1 is also capable of comparing a wear level development of a monitored wear part 5, 6 of the brush manufacturing machine 1 with at least one wear level development recorded in the past. The degree of wear development can thus act as an input variable for the control. The comparison of the current wear level development with a wear level development stored in the control unit 2 and / or in the memory 2a connected to it is carried out with the aid of the control unit 2. The control unit 2 then triggers a targeted reaction when the current wear level development from the recorded wear level development in deviates from a defined dimension. In response to a different degree of wear, a message, in particular a warning message 17, can be output to a terminal device 18 serving as actuator 4.
It is also possible, in response to such a deviating degree of wear, to find a replacement part for the monitored one
Wear parts 5, 6 of the brush manufacturing machine 1 with the brush manufacturing machine 1 or with a PPS system 19 connected to the brush manufacturing machine 1 can be requested autonomously. Furthermore, the brush production machine 1 can autonomously carry out a self-diagnosis and / or error analysis in the case of an identified critical wear level development by means of its control unit 2 and try to counteract the negative wear level development by adapting defined process parameters (see reference number 20).
Thus, the brush manufacturing machine 1 is set up, in particular by its control unit 2, to regulate itself back to a correct state when it has determined an incorrect state. This is preferably done by the brush manufacturing machine 1 specifically changing a process parameter, in particular by actuating at least one actuator 4, 11, 14 of the brush manufacturing machine 1. The resulting changes and their effects are tracked using at least one sensor 3, 12, 16 of the brush manufacturing machine 1 and analyzed and evaluated by the control unit 2 in order to make further adjustments to at least one process parameter if necessary. This continues until the brush manufacturing machine 1 has autonomously returned to its correct target state.
FIG. 1 shows a flow chart of an embodiment of a method according to the invention. On the right side of FIG. 1 it is shown how the method works according to the invention. The left half of FIG. 1 shows a process sequence which corresponds to the prior art. At the beginning of the operation of the brush manufacturing machine 1, it is in an optimal state
Condition (100%). Over time, the condition of the brush making machine 1, e.g. by wear of a wearing part 5, to 98% and finally to 80% of the initial state. As soon as the brush manufacturing machine 1 has reached the 80 percent state, it issues a warning message. This warning message can be perceived by an operator 21 of the brush manufacturing machine 1. The warning message causes the operator 21 of the brush manufacturing machine 1 to carry out an error analysis and, by manual changes to at least one process parameter of the brush manufacturing machine 1, changes the latter to an improved state, e.g. Attributed to 90%. The brush manufacturing machine 1 can be gradually returned to its optimal starting state with the help of the operator 21 over possibly several iterations. However, this procedure requires a high level of qualification and also a great deal of experience of the operator 21. If neither is available, it may take a disproportionately long time to repair the brush manufacturing machine 1.
According to the right half of FIG. 1, an intervention by an operator 1 of the brush manufacturing machine 1 is not necessary. On the basis of the optimal state (100%) of the brush manufacturing machine 1, its state also deteriorates here with the operation of the brush manufacturing machine 1. Since the brush manufacturing machine 1 monitors itself with the aid of the means described in detail above, in particular with the aid of its control unit 2, it can autonomously initiate reactions and countermeasures as soon as its state drops to 98% in order to target the initial state, which is the defined target state here is to fix back.
To inform an operator 21, the brush manufacturing machine 1 can also output messages / warning messages 17 here. It is advantageous that the brush manufacturing machine 1 makes the necessary adjustments e.g. by varying at least one process parameter / machine parameter of the brush manufacturing machine 1 itself. With the aid of its at least one sensor 3, the brush manufacturing machine 1, in particular its control unit 2, can check the effectiveness of the changes made and, if necessary, make further adjustments.
Figure 2 shows another example of a method according to the invention. The method according to the invention is again shown on the right-hand side of FIG. 2, while a method is shown on the left-hand side of FIG. 2 which corresponds to the prior art. Starting from an optimal state of 100% of the brush manufacturing machine 1, the condition of a wearing part 5, a drive chain, also deteriorates here during the operation of the brush manufacturing machine 1. In the methods known from the prior art, the brush manufacturing machine 1 continues to be operated as long as until the wear part 5 fails, i.e. the drive chain breaks here. This leads to an unplanned downtime / failure of the brush manufacturing machine 1, which can lead to major problems in automated production. The brush production machine 1 does issue a warning / fault message 17. However, it takes some time until the operator 21 of the brush manufacturing machine 1 has found the fault and has ordered a spare part for the wear part 5. If the spare part for the wearing part 5 is not in stock, it is necessary to order the spare part for the wearing part 5 from a supplier 22 of the wearing part 5. Until the spare part for the wearing part 5 has been delivered, a certain time passes again in which the brush production machine 1 cannot produce. It is not possible to restart production until the operator 21 has installed the replacement part for the wearing part 5.
In comparison, the method according to the invention, which is illustrated on the right-hand side of FIG. 2, completely avoids unplanned downtimes. In the method according to the invention, the wearing part 5, here the drive chain, is also affected by wear during the operation of the brush manufacturing machine 1.
However, the wear part 5 is continuously monitored here during the operation of the brush manufacturing machine with the aid of a sensor 3, here a camera 16. If it is determined that a degree of wear of the wearing part 5 has increased and therefore production at full power is no longer possible, the brush manufacturing machine 1 issues a warning message 17. In a further step, the brush manufacturing machine 1 autonomously orders a spare part for the monitored and soon to be replaced wearing part 5. The operator 21 of the brush manufacturing machine 1 is informed of this in turn. Either this ordering process takes place completely autonomously, or wait for the order 21 to be released by the operator 21. The order is finally transmitted to a supplier 22 for the spare part of the wearing part 5. The supplier 22 processes the order and confirms it by reporting the expected costs and an expected delivery date.
In the meantime, the brush manufacturing machine 1 can initially produce with undiminished performance. If the degree of wear increases
Wear part 5 continues to increase, the performance of the brush manufacturing machine 1, here a drive 11 of the brush manufacturing machine 1 e.g. can be reduced to a value of 80% of the output power.
In this way, the service life of the wearing part 5 can be extended until the spare part for the wearing part 5 has been delivered and can be installed.
The invention is concerned with improvements in the technical field of manufacturing brushes.
In particular, an improvement is proposed as a brush manufacturing machine 1, which is set up to carry out a method for producing brushes.
It is provided here that a control unit 2 of the brush manufacturing machine 1 autonomously triggers a reaction depending on an input variable in order to control the brush manufacturing machine 1 at least indirectly in a defined target state.
LIST OF REFERENCE SIGNS 1 brush manufacturing machine 2 control unit 2a memory 2b signal connection 3 sensor 4 actuator 5 wear part 6 bundle pickup 7 material box 8 stuffing tool 9 brush body 10 holding device 11 drive 12 pressure sensor 13 bristle filaments 14 material presser 15 compartment notch 16 camera 17 warning message 18 terminal device 19 PPS system 20 adjustment of process parameters 21 Operator 22 supplier

权利要求:
Claims (19)
[1]
1. A method for producing brushes using a brush manufacturing machine (1), wherein a control unit (2) of the brush manufacturing machine (1) autonomously triggers a reaction depending on an input variable in order to control the brush manufacturing machine (1) at least indirectly in a defined desired state.
[2]
2. The method according to claim 1, wherein a size defined by the brush manufacturing machine (1), in particular by machine learning, autonomously defined and / or an actual value of a particular physical size and / or a process parameter of the brush manufacturing machine (1) is used as the input size, the / which is / are determined with the aid of at least one sensor (3, 12, 16) of the brush manufacturing machine (1), and / or wherein the input size is stored in a memory (2a), in particular the brush manufacturing machine (1), which is at least temporarily connected to the control unit (2). , is saved.
[3]
3. The method of claim 1 or 2, wherein the control unit of the brush manufacturing machine (1) in response actuates at least one actuator (4, 11, 14) of the brush manufacturing machine (1), whereby the brush manufacturing machine (1) is controlled in the defined target state.
[4]
4. The method according to any one of the preceding claims, wherein the brush manufacturing machine (1), in particular the control unit (2) of the brush manufacturing machine (1), autonomously defines the desired state, in particular on the basis of the input size, a predetermined production program and / or one of the
Brush-making machine (1), in particular the control unit (2) of the brush-making machine (1).
[5]
5. The method according to any one of the preceding claims, wherein the brush manufacturing machine (1), in particular the control unit (2) of the brush manufacturing machine (1), learns by machine, preferably from previously carried out control processes, to carry out the reaction in an optimized manner, in particular as a reaction the actuator (4, 11, 14) to be optimized to achieve the defined target state.
[6]
6. The method according to any one of the preceding claims, wherein a degree of wear of a wearing part (5, 6) of the brush manufacturing machine (1) is used as the input variable, the degree of wear being determined at least indirectly using at least one sensor (3, 12, 16).
[7]
7. The method according to any one of the preceding claims, wherein a size is used as the input size, which represents a stock of production material that is available for production on the brush manufacturing machine (1), the stock and / or the size at least indirectly using at least of a sensor (3, 12, 16) is / are determined.
[8]
8. The method according to claim 1, wherein in response a drive power of the brush manufacturing machine (1), in particular at least one drive (11) of the brush manufacturing machine (1), preferably with the aid of an actuator (4, 11, 14), to a defined value, for example set to a value of 90% or 80% of an output power, preferably reduced if the input size,
in particular the degree of wear, or a value derived from it, has reached a defined limit.
[9]
9. The method according to any one of the preceding claims, wherein a wear degree development of a monitored wear part of the brush manufacturing machine (1) is used as input variable, the wear degree development being compared with at least one wear degree development recorded in the past, in particular with the aid of the control unit (2), preferably a reaction is triggered when the current wear level development deviates from the recorded wear level development to a defined extent, in particular a message relating to the wear level development is output as a reaction and / or a replacement part for the monitored wear part (5, 6) is requested autonomously by the brush manufacturing machine (1) and / or by a PPS system (19) connected to the brush manufacturing machine (1) and / or a self-diagnosis and / or fault analysis is carried out autonomously as a reaction.
[10]
10. The method according to any one of the preceding claims, wherein the brush manufacturing machine (1), in particular with the aid of its control unit (2), regulates itself back into the desired state when an incorrect state has been determined, preferably by the brush manufacturing machine (1) at least one process parameter , in particular by actuation of at least one actuator (4, 11, 14) of the brush manufacturing machine (1), specifically changed, the change and its effect are tracked with the aid of at least one sensor and, if necessary, makes further adjustments to at least one process parameter until it has reached the desired state .
[11]
11. Brush manufacturing machine (1) set up to carry out the method according to one of the preceding claims.
[12]
12. Brush manufacturing machine (1) according to claim 11, wherein the brush manufacturing machine (1) has a control unit (2), at least one sensor (3) and / or at least one actuator (4, 11, 14), wherein the control unit (2) is set up to actuate the actuator (4, 11, 14) autonomously in order to regulate the brush manufacturing machine (1) in a defined target state.
[13]
13. Brush manufacturing machine (1) according to claim 12, wherein the sensor (3) and the actuator (4, 11, 14) are connected to the control unit (2) in terms of signal technology and wherein the sensor (3) is set up to provide an actual value of a particular physical quantity and / or at least one process parameter of the brush manufacturing machine (1) which can be influenced with the actuator (4, 11, 14), and / or wherein the brush manufacturing machine (1) has a memory (2a) in which an input size can be stored and to which the control unit (2) has access.
[14]
14. Brush manufacturing machine according to one of the preceding claims, wherein the brush manufacturing machine (1), in particular one or the control unit (2) of the brush manufacturing machine (1), is set up for the autonomous generation of an input variable.
[15]
15. Brush manufacturing machine (1) according to one of the preceding claims, characterized in that the brush manufacturing machine (1), in particular the control unit (2) of the brush manufacturing machine (1), is set up for machine learning.
[16]
16. Brush manufacturing machine (1) according to one of the preceding claims, wherein an input size taken into account by the brush manufacturing machine (1) is a degree of wear of a wearing part (5) and the brush manufacturing machine has at least one or the at least one sensor that is set up to measure a degree of wear Wear part (5) of the brush manufacturing machine (1) to be determined.
[17]
17. Brush manufacturing machine (1) according to one of the preceding claims, wherein the brush manufacturing machine has one or the at least one actuator, which is set up to change a process parameter and / or a setting of the brush manufacturing machine (1) to the brush manufacturing machine (1) in to regulate the target state.
[18]
18. Brush manufacturing machine (1) according to one of the preceding claims, wherein the control unit (2), in particular by one or the actuator (4) is set up to change a drive power of the brush manufacturing machine (1), in particular to reduce the brush manufacturing machine ( 1) to regulate in the target state.
[19]
19. Brush manufacturing machine (1) according to one of the preceding claims, wherein the brush manufacturing machine (1) as at least one sensor (3) is a vibration sensor, one
Force sensor, a pressure sensor (12), a volume flow sensor, a temperature sensor, an optical sensor, a measuring circuit and / or a camera (16).

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同族专利:

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BE1026493A1|2020-02-18|

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DE102018118545A1|2020-02-06|

引用文献:

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公开号 | 申请日 | 公开日 | 申请人 | 专利标题

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US6763278B1|2002-04-26|2004-07-13|Advanced Micro Devices, Inc.|Operating a processing tool in a degraded mode upon detecting a fault|

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US20140156057A1|2012-12-04|2014-06-05|Fanuc Corporation|Machine tool including numerical controller with function to determine replacement time for maintenance component|

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WO2017116627A1|2016-01-03|2017-07-06|Presenso, Ltd.|System and method for unsupervised prediction of machine failures|

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法律状态:
2020-08-26| FG| Patent granted|Effective date: 20200717 |

优先权:

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申请号 | 申请日 | 专利标题

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DE102018118545.6A|DE102018118545A1|2018-07-31|2018-07-31|Method of making brushes and brush making machine|

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