CN108112241B

CN108112241B - roll forging machine and roll forging method

Info

Publication number: CN108112241B
Application number: CN201680037122.5A
Authority: CN
Inventors: 越智俊夫; 克劳斯·贝格拉尔-巴奇; 莱因哈德·弗里茨
Original assignee: Manyo Co Ltd
Current assignee: Manyo Co Ltd
Priority date: 2015-06-22
Filing date: 2016-06-14
Publication date: 2019-12-17
Anticipated expiration: 2036-06-14
Also published as: DE112016002792T5; JP2017006947A; WO2016207016A1; JP6588743B2; KR20180021099A; CZ308188B6; JP2018528862A; CZ201818A3; CN108112241A; KR102037889B1

Abstract

The invention provides a roll forging machine and a roll forging method. The roll forging machine includes: a pair of roll dies provided on the pair of roll driving shafts, and having a plurality of forming dies formed thereon, respectively; and a carrying unit for carrying the material to be molded to the mold molding position, the receiving position and the carrying-out position. The carrying unit includes: a first robot having a robot hand that moves along a first rectangular movement path including a straight in-forming movement path connecting positions corresponding to forming positions having a plurality of forming dies and a first turning-off path that is spaced apart from the straight in-forming movement path by a predetermined amount on one side of the straight in-forming movement path; and a second robot having a manipulator moving along a second rectangular moving path including a straight in-formation moving path and a second turn-off path spaced apart from the straight in-formation moving path on the other side thereof by a predetermined amount.

Description

roll forging machine and roll forging method

Technical Field

The present invention relates to a roll forging machine and a roll forging method for performing die forming on a material to be forged by using a pair of roll dies. More specifically, the present invention relates to a roll forging machine and a roll forging method that feed a material to be formed to a pair of roll dies one after another with two carrying units and perform die forming continuously using the pair of roll dies to improve productivity.

background

With regard to the production of forgings as metal parts, there is known a working method of forming a desired product by a forging press or the like after a material has been preformed in a desired shape in advance. Such preforming is also called preforging or the like, and a roll forging machine (also called a forging roll) is known as a forging machine for performing such work (for example, see patent document 1).

Further, a technique for a manipulator for forging a roller is known in which even if an impact is applied to a metal material during roll forging in a forging roller, such an impact can be prevented from being transmitted to the manipulator (for example, see patent document 2). In such a technique, a manipulator is provided on a wrist of a second arm of the robot, and a configuration is disclosed in which the robot is of an articulated type having a first arm, a second arm, and the like, and the movement of the manipulator is controlled by a robot control unit. Further, a forging roll technique is known which requires low cost without increasing installation space, shortens cycle time by one half, and enables an expensive forging press to be efficiently utilized (for example, see patent document 3).

[ Prior art documents ]

[ patent document ]

Patent document 1: examined patent application publication No. S52-8783 (JP, S52-8783, B)

Patent document 2: examined patent application publication No. H1-33262 (JP, H01-33262, B)

Patent document 3: patent application publication No. H5-169176 (JP, H05-169176, A)

patent document 4: patent application publication No. 3435314 (JP,3435314, B)

Disclosure of Invention

[ problems to be solved by the invention ]

On the other hand, there are many demands for a roll forging machine to improve productivity. However, although patent documents 1 and 2 disclose a construction technique of a roll forging machine, these patent documents do not disclose improvement of productivity of the roll forging machine. Further, patent document 3 discloses a construction technique of a robot arm, but does not disclose further improvement in productivity of a roll forging machine. Further, although patent document 4 discloses a technique of forging a roll aimed at shortening the cycle time, the technique requires two constituent sets of rolls (i.e., a portion for performing roll forming, such as a first roll having a first jig (gripping) and a second roll having a second jig) and still achieves only a half-reduction in the cycle time as compared with an existing roll forging machine having one constituent set of rolls. Therefore, many problems remain to be improved.

That is, there is a problem in that productivity is lowered since roll forging is not performed in the following steps: a step in which the billet is pushed out with the first push rod rotated and is caused to be gripped by the first gripper, a step in which the billet is pushed out with the second push rod rotated and is caused to be gripped by the second gripper, a step in which feeding-out is performed by the first outward conveyor or the second outward conveyor, and so on. Further, the technique of patent document 4 requires a first set of rollers and a second set of rollers, which is expensive and poses problems such as economic problems, conservation problems when molding is not performed, and the like.

The present invention has been made to solve the above-mentioned problems, thereby achieving the following object.

An object of the present invention is to provide a roll forging machine and a roll forging method in which two carrying units corresponding to a pair of roll dies are provided, a material to be forged is successively fed to the pair of roll dies by the two carrying units, and die forming is continuously performed using the pair of roll dies to improve productivity.

another object of the present invention is to provide a roll forging machine and a roll forging method in which interference between robot arms is prevented in the case where two carrying units corresponding to a pair of roll dies are provided.

[ means for solving problems ]

The present invention provides the following features to achieve the above-mentioned objects.

The roll forging machine according to the first aspect of the present invention includes:

a pair of roll driving shafts provided to be rotatable on a body of the roll forging machine and rotated by driving of a driver,

A pair of roller dies provided on the pair of driving shafts, respectively, and having a plurality of forming dies formed thereon with a predetermined interval therebetween, and

A carrying unit for carrying a material to be molded to a receiving position of the material to be molded, a molding position of the pair of roll molds having the plurality of molding dies, and a molded product carrying-out position;

Wherein the carrier unit comprises:

A first robot having a robot arm that moves along a first rectangular movement path including a straight in-forming movement path connecting positions corresponding to the forming positions with the plurality of forming dies and a first turning-off path that is spaced apart from the straight in-forming movement path on one side of the straight in-forming movement path by a predetermined amount, and

a second robot having a manipulator moving along a second rectangular moving route including the straight in-formation moving route and a second turning-off route spaced apart from the straight in-formation moving route on the other side thereof by a predetermined amount; and is

Wherein the first robot and the second robot are respectively controlled such that when the manipulator of the first robot moves along the straight in-shape movement route, the manipulator of the second robot moves along a portion of the second rectangular movement route other than the straight in-shape movement route, and when the manipulator of the second robot moves along the straight in-shape movement route, the manipulator of the first robot moves along a portion of the first rectangular movement route other than the straight in-shape movement route.

the roll forging machine according to the second aspect of the invention: in the first aspect, the receiving position of the material to be formed and the formed article carrying-out position are provided in an extension of the straight in-forming moving route.

The roll forging machine according to the third aspect of the invention: in any one of the first to second aspects, the first robot and the second robot are each an articulated robot.

The roll forging machine according to the fourth aspect of the invention: in a third aspect, each of the first robot and the second robot comprises: a rotating base which can rotate; a plurality of arms connected in series to be swung or rotated relative to each other, and one end of the arms connected in series is connected to the rotation base to be capable of swinging; and a robot arm having a material to be formed gripping portion and connected to the other end of the serially connected arms.

A roll forging machine according to a fifth aspect of the present invention: in any one of the first to fourth aspects, one of the first and second robots is a floor type robot, and the other is a suspension type robot.

A roll forging machine according to a sixth aspect of the present invention: in any one of the first to fourth aspects, the first robot and the second robot are floor-type robots disposed at respective positions having different heights.

The roll forging machine according to the seventh aspect of the invention: in any one of the first to sixth aspects, the manipulator of the first robot moves from a receiving position to a mold forming first step position when the manipulator of the second robot moves from a forming final step position to a formed article carry-out position, and the manipulator of the second robot moves from a receiving position to a mold forming first step position when the manipulator of the first robot moves from a forming final step position to a formed article carry-out position.

the roll forging method according to the eighth aspect of the invention: a roll forging machine was used comprising:

A pair of roller dies provided on the pair of driving shafts, respectively, and provided with a plurality of forming dies for forming, the plurality of forming dies having a predetermined interval therebetween, and

A carrying unit for carrying a material to be molded to a receiving position of the material to be molded, a molding position of the pair of roll molds having the plurality of molding dies, and a molded product carrying-out position,

The carrier unit includes:

a first robot having a robot arm that moves along a first rectangular movement path including a straight in-forming movement path connecting positions corresponding to the forming positions with the plurality of forming dies and a first turning-off path that is spaced apart from the straight in-forming movement path on one side of the straight in-forming movement path by a predetermined amount; and a second robot having a manipulator moving along a second rectangular moving route including the straight in-formation moving route and a second turning-off route spaced apart from the straight in-formation moving route on the other side thereof by a predetermined amount;

wherein the manipulator of the second robot moves along a portion of the second rectangular movement route other than the straight in-shape movement route when the manipulator of the first robot moves along the straight in-shape movement route,

When the manipulator of the second robot moves along the straight in-shape movement route, the manipulator of the first robot moves along a portion of the first rectangular movement route other than the straight in-shape movement route, and

either one of the first robot and the second robot can perform forming using the pair of roll dies.

The roll forging method according to the ninth aspect of the invention: in the eighth aspect, when the manipulator of the second robot moves from the forming final-step position to the formed article carry-out position, the manipulator of the first robot moves from the receiving position to the mold forming first-step position, and

the robot hand of the second robot moves from the receiving position to the mold forming first step position when the robot hand of the first robot moves from the forming final step position to the carry-out position.

[ advantageous effects of the invention ]

according to the roll forging machine of the present invention, it is possible to successively perform forming of a material to be formed gripped by a first carrying unit (first robot) or a second carrying unit (second robot) using a pair of dies while keeping the pair of roll dies continuously rotating, thereby improving productivity. For example, when the robot hand of the first robot (or the second robot) moves from the material-to-be-formed receiving position to the first mold forming step position (e.g., the first step position), the robot hand of the second robot (or the first robot) moves from the final mold forming step position (e.g., the fourth step position) to the formed article carry-out position. In this way, the hand of the first robot and the hand of the second robot can be prevented from interfering with each other, and molding can be continuously performed by the pair of molds.

For such roll forging machines, two robots are operated in turn. The time for the feeding operation of the material to be formed and the time for the unloading of the formed article are therefore not lost times at present, but these are lost times in conventional roll forging machines. Further, this roll forging machine has the following configuration: the two robots are separately disposed in the upper and lower positions to avoid interference therebetween, thus enabling the two carrying units to be operated alternately. Therefore, it is possible to achieve an improvement in productivity of the roll forging machine.

Further, although two sets of roller dies are required for improving productivity in the conventional roll forging machine, such a roll forging machine does not require two sets of roller dies, so that reduction in die manufacturing cost, reduction in die storage space, reduction in die replacement operation time, and the like can be achieved. Thus, a great economic advantage can be obtained.

The roll forging method in the roll forging machine is a roll forging method in which roll forging (forming with a pair of roll dies) is performed by controlling two robots in the following manner: while the hand of one robot moves along the in-forming movement path, the hand of the other robot moves along the first or second turnaround path. Therefore, the robot arms of the two robots do not interfere with each other, and forming is performed by feeding the material to be formed to a pair of roller dies one after another, thus achieving an improvement in productivity.

Drawings

Fig. 1 is a front view showing an embodiment of a roll forging machine according to the present invention.

Fig. 2 is a plan view of the roll forging machine.

figure 3 is a front view of a robot in a roll forging machine, with a portion of the robot shown in cross-section.

Fig. 4 is a side view of the robot.

Fig. 5 is an explanatory view schematically showing a roller die in the roll forging machine.

Fig. 6 is an explanatory view showing the movement routes of the manipulators of the first robot and the second robot.

Fig. 7 is an operation explanatory view showing a relationship among the first robot, the second robot, and the roll forging machine.

fig. 8 is an explanatory view 1 schematically showing a positional relationship between the first robot and the second robot.

Fig. 9 is an explanatory view 2 schematically showing a positional relationship between the first robot and the second robot.

Fig. 10 is an explanatory view 3 schematically showing a positional relationship between the first robot and the second robot.

Fig. 11 is an explanatory view 4 schematically showing a positional relationship between the first robot and the second robot.

[ description of symbols ]

1: roll forging machine

2: main body

3: first roller drive shaft

4: first roll die 5: second roller drive shaft

6: second roll die

7: hanging base

8: formed article carrying-out unit

10: first robot

11: first robot base

12. 32: first rotating mechanism

13. 33: first rotary base

14. 34: first swing mechanism

15. 35: first arm

16. 36: second swing mechanism

17. 37: second arm

18. 38: second rotating mechanism

19. 39: third arm

20. 40: third swinging mechanism

21. 41: the fourth arm

25. 45, and (2) 45: mechanical arm

251. 251: grasping pawl

252: hand opening and closing drive unit

252 a: cylinder body

253: hand base

254: hand rotating shaft

26: hand rotation and positioning unit

261: servo motor

30: second robot

31: second robot base

50A: first moving route

50B: second moving route

51: moving route in forming

52: first switching-off route

53: second diversion route

P1: receiving position

P2: first step position

p3: second step position

P4: third step position

P5: fourth step position

P6: carry-out position

P7, P17: pivoted open position

P8, P18: position before reception

Detailed Description

the configuration for implementing the roll forging machine and the roll forging method according to the present invention will be explained below.

Fig. 1 is a front view showing an embodiment of a roll forging machine according to the present invention, fig. 2 is a plan view of the roll forging machine, fig. 3 is a front view of a manipulator in the roll forging machine, in which a part of the manipulator is shown in section, fig. 4 is a side view of the manipulator, fig. 5 is an explanatory view schematically showing a roll mold in the roll forging machine, fig. 6 is an explanatory view showing a moving route of the manipulator of a first robot and a second robot, and fig. 7 is an operational explanatory view showing a relationship among the first robot, the second robot, and the roll forging machine.

Fig. 8 is an explanatory view 1 schematically showing a positional relationship between the first robot and the second robot, fig. 9 is an explanatory view 2 schematically showing a positional relationship between the first robot and the second robot, fig. 10 is an explanatory view 3 schematically showing a positional relationship between the first robot and the second robot, and fig. 11 is an explanatory view 4 schematically showing a positional relationship between the first robot and the second robot.

Main body of roll forging machine

The configuration of the roll forging machine 1 will be explained with reference to fig. 1 to 5. The roll forging machine 1 is constituted by a main body 2 of the roll forging machine, a first robot 10 as a first carrying unit, a second robot 30 as a second carrying unit, and the like.

The first roller drive shaft 3 and the second roller drive shaft 5 are rotatably held on the main body 2 of the roll forging machine. The first roller drive shaft 3 and the second roller drive shaft 5 are arranged to form a paired configuration in which the axes of the first roller drive shaft 3 and the second roller drive shaft 5 are parallel to each other. Both ends of the first roller drive shaft 3 are held on the main body 2 by bearings (not shown in the figure). Similarly, both ends of the second roller driving shaft 5 are also held on the main body 2 by bearings (not shown in the drawings). The first roller drive shaft 3 is driven to rotate by an output transmitted from the servo motor SM via a transmission gear mechanism (not shown in the figure). The second roller drive shaft 5 is driven to rotate by an output transmitted from a servo motor (not shown in the figure, but similar to the servo motor for the first roller drive shaft 3) via a transmission gear mechanism (not shown in the figure). In other words, the first roller drive shaft 3 and the second roller drive shaft 5 (configured as a pair of upper and lower shafts) are configured to be driven to rotate by a pair of servo motors SM, respectively.

Here, the first roller drive shaft 3 and the second roller drive shaft 5 are normally controlled to rotate and stop at the same time. Further, the first roller drive shaft 3 and the second roller drive shaft 5 are normally controlled to rotate in opposite directions (direction R and direction R' shown in fig. 5) to each other and at the same rotation rate. The first roll mold 4 is detachably fixed on the outer circumferential surface of the first roll driving shaft 3, and the second roll mold 6 is detachably fixed on the outer circumferential surface of the second roll driving shaft 5.

The first roller die 4 is formed with a plurality of forming dies 4a with a certain distance therebetween for performing die forming by roll forging (forming with a pair of roller dies). The second roll die 6 is formed with a plurality of forming dies 6a with a certain distance therebetween for performing roll forging.

Carrying unit

As shown in fig. 1 and 2, a first carrying unit and a second carrying unit for feeding a material m to be formed to the forming dies 4a and 6a, performing die forming, and carrying out an article formed to have a desired configuration are provided in front of the main body 2 of the roll forging machine. The first carrier unit is a first robot 10 called an articulated robot, and the second carrier unit is a second robot 30 called an articulated robot. Although the first robot 10 and the second robot 30 are well known in the art as an articulated robot enabling three-dimensional movement of a manipulator, the configuration will be briefly explained here to make the explanation of such a configuration easier to understand.

first robot

the first robot 10 is a suspension type robot configured to be suspended on the suspension base 7. As the hanging base body, the hanging base 7 is constructed such that an upper plate 73 is fixed on upper ends of three columns 72, the three columns 72 being fixed on the base plate 71 and extending vertically, respectively.

The first robot base 11 of the first robot 10 is fixed to the bottom side of the upper plate 73. A first rotation mechanism 12 is provided between the first robot base 11 and the first rotation base 13. The first rotating base 13 performs a rotating movement about the axis C1 (in the direction of arrow θ 1) with respect to the first robot base 11, and is positioned to be in a desired rotational position. A first swing mechanism 14 is provided between the first rotating base 13 and the first arm 15. The first arm 15 performs a swinging motion about the axis C2 (in the direction of the arrow θ 2) with respect to the first rotating base 13, and is positioned to be in a desired swinging position. A second swing mechanism 16 is provided between the first arm 15 and the second arm 17. The second arm 17 performs a swinging motion about the axis C3 in the direction of the arrow θ 3 with respect to the first arm 15, and is positioned to be in a desired swinging position.

A second rotating mechanism 18 is provided between the second arm 17 and the third arm 19. The third arm 19 performs a rotational movement about the axis C4 (in the direction of arrow θ 4) relative to the second arm 17 and is positioned in a desired rotational position. A third swing mechanism 20 is provided between the third arm 19 and the fourth arm 21. The fourth arm 21 performs an oscillating movement about the axis C5 with respect to the third arm 19 in the direction of the arrow θ 5 and is positioned in the desired oscillation position. A manipulator 25 is attached to the fourth arm 21. In the first robot 10, the first rotating mechanism 12, the second rotating mechanism 18, the first swinging mechanism 14, the second swinging mechanism 16, the third swinging mechanism 20, and the like are controlled by a first robot control device (not shown in the figure) that controls the driving and positioning of a servo motor (not shown in the figure).

the second robot 30 is a floor type robot. The second robot base 31 of the second robot 30 is fixed on the upper face of a base plate placed on the floor. A first rotation mechanism 32 is provided between the second robot base 31 and the first rotation base 33. First rotating base 33 performs a rotating movement about axis C11 (in the direction of arrow θ 11) with respect to second robot base 31, and is positioned in a desired rotational position. A first swing mechanism 34 is provided between the first rotating mechanism 33 and the first arm 35. The first arm 35 performs an oscillating movement about the axis C12 with respect to the first rotating base 33 in the direction of the arrow θ 12, and is positioned in a desired oscillation position. A second swing mechanism 36 is provided between the first arm 35 and the second arm 37. The second arm 37 performs a swinging motion about the axis C13 in the direction of the arrow θ 13 with respect to the first arm 35, and is positioned to be in a desired swinging position.

A second rotating mechanism 38 is provided between the second arm 37 and the third arm 39. The third arm 39 performs a rotational movement about the axis C14 (in the direction of arrow θ 14) relative to the second arm 37, and is positioned in a desired rotational position. A third swing mechanism 40 is provided between the third arm 39 and the fourth arm 41. The fourth arm 41 performs a swinging movement about the axis C15 with respect to the third arm 39 in the direction of the arrow θ 15, and is positioned in a desired swinging position. A robot arm 45 is attached to the fourth arm 41. In the second robot 30, the first rotating mechanism 32, the second rotating mechanism 38, the first swinging mechanism 34, the second swinging mechanism 36, the third swinging mechanism 40, and the like are controlled by a second robot control device (not shown in the figure) that controls the driving and positioning of a servo motor (not shown in the figure).

Mechanical arm

the manipulator 25 of the first robot 10 and the manipulator 45 of the second robot 30 will be explained with reference to fig. 3 and 4. Here, the robot 25 has the same configuration as the robot 45. Therefore, the construction will be explained taking the robot arm 25 as an example.

in the robot 25, a robot base (i.e., the hand base 253) is attached to the fourth arm 21 or the fourth arm 41. The robot rotation shaft (i.e., hand rotation shaft 254) is provided to be rotatably supported in the hand base 253 by a bearing 255. A pair of gripping pawls 251, 251 that grip the material m to be formed is provided at the front side of the hand rotating shaft 254. A manipulator opening and closing driving unit (i.e., a hand driving unit 252) is provided in the rear side of the hand rotating shaft 254. A connecting rod (not shown) and a linkage (not shown) for opening and closing the hand are provided between the hand driving unit 252 and the pair of grasping pawls 251, 251. The hand driving unit 252 reciprocates the connection rod in a length direction (parallel to the axis C6 shown in fig. 3) of the hand base 253. A linkage for opening and closing the hand converts the reciprocating movement of the connecting rod into the opening and closing movement of the grasping pawls 251, 251.

In other words, the pair of grasping pawls 251, 251 perform opening and closing actions by the operation of the hand driving unit 252 through the linkage for opening and closing the hand. A clamping spring (not shown in the drawings) is provided in the hand driving unit 252 for retracting the connecting rod backward to perform the closing movement of the pair of grasping pawls 251, 251. A cylinder 252a is provided in the hand driving unit 252 to push the connecting rod forward against the clamping spring when supplied with pressurized fluid (e.g., pressurized oil). The forward pushing movement of the connecting rod by the cylinder 252a causes the opening movement of the pair of grasping pawls 251, 251 by the linkage for opening and closing the hand. When the supply of pressurized fluid to the cylinder 252a is stopped, the clamp spring retracts the connecting rod rearward with its stored force. The clamping spring moving the connecting rod backward causes the pair of grasping pawls 251, 251 to perform a closing movement through a linkage for opening and closing the hand. The forward and backward movement of the connecting rod by the hand driving unit 252 can be detected by the opening and closing movement detecting portion 252 b. Such opening and closing mechanisms of manipulators including linkages, connecting rods, etc. for opening and closing hands are well known in the art and therefore will not be explained in further detail herein.

A servomotor 261 for rotating and positioning the robot (hereinafter referred to as a servomotor for a rotation shaft) is attached to the hand base 253 to rotate the hand rotation shaft 254 about an axis C6 (in the direction of an arrow θ 6 shown in fig. 3). A toothed pulley-toothed belt mechanism is provided between the output shaft of the servomotor 261 for rotating the shaft and the hand rotating shaft 254. That is, one toothed pulley is attached to the output shaft of the servomotor 261 for rotating the shaft, and the other toothed pulley 262 is attached to the hand rotating shaft 254. The toothed belt is looped over one toothed pulley and the other toothed pulley 262 to encircle the one toothed pulley and the other toothed pulley 262. The servomotor 261 for rotating the shaft and the toothed pulley-toothed belt mechanism constitute a robot rotating and positioning unit (i.e., the hand rotating unit 26). In the case where the hand rotating unit is provided, for example, roll forging (forming with a pair of roll dies) may be performed in such a manner that the hand rotating shaft 254 is rotated by 90 degrees in the direction around the axis C6. Here, the toothed pulley-toothed belt mechanism may be replaced by another transmission mechanism (e.g., a gear mechanism).

a pair of roller dies

The forming work (roll forging) by the pair of roll dies 4, 6 will be explained with reference to fig. 5, 6. In this roll forging machine, the robot arm 25 and the robot arm 45 move along the routes shown in fig. 6, respectively. On the other hand, in the roll forging machine 1, four forming dies 4a (4a1, 4a2, 4a3, and 4a4) are formed on the first roll die 4, and four forming dies 6a (6a1, 6a2, 6a3, and 6a4) are formed on the second roll die 6, respectively. The molding die 4a and the molding die 6a constitute a pair of molding dies. Specifically, the molding die 4a1 and the molding die 6a1 constitute a first molding die F1, the molding die 4a2 and the molding die 6a2 constitute a second molding die F2, the molding die 4a3 and the molding die 6a3 constitute a third molding die F3, and the molding die 4a4 and the molding die 6a4 constitute a fourth molding die F4 (see fig. 5).

In response to the above, the first robot 10 and the second robot 30 move the hand 25 and the hand 45 to the first step position P2 corresponding to the first molding die F1, the second step position P3 corresponding to the second molding die F2, the third step position P4 corresponding to the third molding die F3, and the fourth step position P5 corresponding to the fourth molding die F4, respectively. For example, the roll forging machine 1 forms the material to be formed into a desired shape in the first step position P2 using a forming die F1 including a forming die 4a1 and a forming die 6a 1. In other words, the roll forging work (the forming with a pair of dies) is performed on the material to be formed m gripped by the pair of gripping pawls 251, 251 provided on the robot arms 25, 45, respectively, with the first roll die 4 rotating in the direction R shown in fig. 5 and the second roll die 6 rotating in the direction R'.

These first forming die F1, second forming die F2, third forming die F3 and fourth forming die F4 are generally used as follows. With the first molding die F1 at the first step position P2, the material to be molded m is extruded. With the second forming die F2 being in the second step position P3, after the material to be formed m extruded by the forming die F1 is rotated by 90 degrees about the axis C6 by the hand rotating unit 26, correction forming is performed on the widened portion of the extruded material. With the third forming die F3 being in the third step position P4, after the material to be formed m is reversely rotated by 90 degrees about the axis C6 by the hand rotating unit 26, the material to be formed m is extruded. With the fourth forming die F4 at the fourth step position P5, the straightening forming is performed on the widened portion of the material m to be formed that is extruded by the forming die F3, thereby forming a final formed article having a final shape with thin concave and convex surfaces and a substantially circular cross section.

Roll forging method

A roll forging method using the roll forging machine 1 will be explained with reference to fig. 6 to 11. The first roll die 4 and the second roll die 6 rotate at a predetermined rotation frequency. Further, the rotation of the first roller drive shaft 3 and the second roller drive shaft 5 is controlled by the servo motor SM, and the rotational positions of the first roller drive shaft 3 and the second roller drive shaft 5 are synchronized.

As shown in fig. 6, the first movement route 50A is formed such that the manipulator 25 of the first robot 10 moves to occupy the following positions in order: a material-to-be-formed m receiving position (i.e., receiving position P1) for receiving the material-to-be-formed m, which has been heated to a prescribed temperature, from a material-to-be-formed feeding unit (not shown in the drawings); first step position P2; a second step position P3; third step position P4; a fourth step position P5; a formed article carrying-out position (position for carrying out the formed article) for carrying out the formed article onto the formed article carrying-out unit 8 (i.e., carrying-out position P6); a position turning position (side) P7; and a position before receiving the material to be formed (i.e., a position before receiving P8). The first step position P2, the second step position P3, the third step position P4, and the fourth step position P5 are arranged in a line, and form a forming in-process movement route (route for movement in forming) 51 for forming the material m to be formed. The receiving position P1 and the carrying-out position P6 are provided in the extension of the in-forming movement route 51. That is, the robot 25 moves along the first moving route 50A having a frame-shaped (closed-loop) form, the first moving route 50A including the in-forming moving route 51 including the first step position P2, the second step position P3, the third step position P4, and the fourth step position P5 and in which the receiving position P1 to the carry-out position P6 are arranged in a line from the head to the tail and also including the first turning-off route 52, the first turning-off route 52 being spaced apart from the in-forming moving route 51 by a predetermined distance on one side of the in-forming moving route 51 (for example, on the lower side in the illustrated configuration).

the second movement route 50B is formed such that the manipulator 45 of the second robot 30 moves to occupy the following positions in order: a receiving position P1, a first step position P2, a second step position P3, a third step position P4, a fourth step position P5, a carry-out position P6, a swing-out position P17, and a material-to-be-formed-before-reception position (i.e., a before-reception position P18). That is, the robot 45 moves along the second movement route 50B having a frame-shaped (closed-loop) form, the second movement route 50B including the in-forming movement route 51 including the first step position P2, the second step position P3, the third step position P4, the fourth step position P5 and in which the receiving position P1 to the carry-out position P6 are arranged in a line from the head to the tail and also including the second switch-off route 53, the second switch-off route 53 being spaced apart from the in-forming movement route 51 by a predetermined distance on the other side (e.g., on the upper side in the illustrated configuration) of the in-forming movement route 51.

The movements of the first robot 10 and the second robot 30 will be explained, linking them to the movements on the side of the main body 2 of the roll forging machine 1. On the side of the main body 2 of the roll forging machine 1, a first roll driving shaft 3 and a second roll driving shaft 5 rotate at a prescribed rotational frequency. Further explanation will be made with reference to the "movement and operation flowchart" shown in fig. 7.

The manipulator 25 of the first robot 10 moves from the third step position P4 to the fourth step position P5. At this time, the robot hand 45 of the second robot 30 moves from the pre-receiving position P18 to the receiving position P1 (see fig. 9). After the robot arm 25 has moved to the fourth step position P5, the first robot 10 performs forming using the fourth forming die F4. The second robot 30 receives the material to be formed m from the material to be formed feed unit in the receiving position P1, wherein the robot arm grips the material. (step S1)

The robot hand 45 of the second robot 30 having received the material to be formed m moves from the receiving position P1 to the first step position P2. At this time, the robot hand 25 of the first robot 10 moves from the fourth step position P5 to the carry-out position P6, releases the grip of the formed article and transfers the formed article to the formed article carry-out unit 8. After the robot arm 45 has moved to the first step position P2, the second robot 30 performs forming on the material to be formed m gripped by the robot arm 45 using the first forming die F1. (step S2)

The robot hand 45 of the second robot 30 moves from the first step position P2 to the second step position P3. At this time, the hand 25 of the first robot 10 moves from the carry-out position P6 to the turn-off position P7. After the robot hand 45 has moved to the second step position P3, the second robot 30 performs forming on the material to be formed m gripped by the robot hand 45 using the second forming die F2. (step S3)

The manipulator 45 of the second robot 30 moves from the second step position P3 to the third step position P4. At this time, the manipulator 25 of the first robot 10 moves from the rotated-out position P7 to the pre-reception position P8 (see fig. 10). After the robot hand 45 has moved to the third step position P4, the second robot 30 performs forming of the material to be formed grasped by the robot hand 45 using the third forming die F3. (step S4)

The manipulator 45 of the second robot 30 moves from the third step position P4 to the fourth step position P5. At this time, the manipulator 25 of the first robot 10 moves from the pre-reception position P8 to the reception position P1 (see fig. 11). After the robot hand 45 has moved to the fourth step position P5, the second robot 30 performs forming on the material to be formed m gripped by the robot hand 45 using the fourth forming die F4. The robot hand 25 of the first robot 10 receives the material to be formed m from the material to be formed feeding unit. (step S5)

The robot hand 45 of the second robot 30 moves from the fourth step position P5 to the carry-out position P6. At this time, the manipulator 25 of the first robot 10 moves from the receiving position P1 to the first step position P2. After the robot hand 25 has moved to the first step position P2, the first robot 10 performs forming on the material to be formed m gripped by the robot hand 25 using the first forming die F1. The second robot 30 releases the grip of the robot arm 45 in the carry-out position P6 and hands over the formed article to the formed article carry-out unit 8. (step S6)

The manipulator 25 of the first robot 10 moves from the first step position P2 to the second step position P3. At this time, the hand 45 of the second robot 30 moves from the carry-out position P6 to the turn-off position P17. After the robot hand 25 has moved to the step position P3, the first robot 10 performs forming on the material to be formed m gripped by the robot hand 25 using the second forming die F2. (step S7)

The manipulator 25 of the first robot 10 moves from the second step position P3 to the third step position P4. At this time, the robot hand 45 of the second robot 30 moves from the swing-out position P17 to the pre-reception position P18 (see fig. 8). After the robot hand 25 has moved to the third step position P4, the first robot 10 performs forming on the material to be formed m gripped by the robot hand 25 using the third forming die F3. (step S8)

returning to step S1, the molding operation of the material to be molded with the forming die is repeated.

Here, although the foregoing explanation has been made with respect to the configuration of fig. 6 with an example in which the receiving position P1, the first step position P2, the second step position P3, the third step position P4, the fourth step position P5, and the carry-out position P6 are disposed in a line, the receiving position P1 and the carry-out position P6 do not necessarily have to be disposed in the extension of the in-forming movement route 51. For example, the receiving position P1 and/or the carrying-out position P6 may be disposed on the first or second rotary open line. Further, the receiving position P1 and/or the carrying-out position P6 may be provided between the moving route in forming and the first switch-off route or the second switch-off route.

In other words, the following configuration can be realized: the robot hand 25 of the first robot 10 and the robot hand 45 of the second robot 30 do not perform the forming at the same time, and the forming operations of both are shared on the in-forming movement route 51 extending over the first step position P2, the second step position P3, the third step position P4, and the fourth step position P5.

With such a roll forging machine 1, the pair of roll dies 4 and 6 respectively fixed to the pair of drive shafts 3 and 5 are constantly rotated, and the first robot 10 and the second robot 30 are alternately operated in succession to perform a forming work (roll forging) with the pair of roll dies 4 and 6. Therefore, with this kind of roll forging machine 1, the forming by the pair of roll dies 4 and 6 is not stopped at the time of receiving the material m to be formed and handing over the formed product, and therefore, the improvement of productivity is achieved. For example, when the manipulator 25 of the first robot 10 (or the manipulator 45 of the second robot 30) is at the receiving position P1, the manipulator 45 of the second robot 30 (or the manipulator 25 of the first robot 10) is at the fourth step position P5. Further, when the hand 25 of the first robot 10 (or the hand 45 of the second robot 30) is at the carry-out position P6, the hand 45 of the second robot 30 (or the hand 25 of the first robot 10) is at the first step position P2. In this way, the robot hand 25 of the first robot 10 and the robot hand 45 of the second robot 30 do not interfere with each other, and molding is performed by the roller dies 4 and 6 all the time, so that productivity can be improved.

Further, the first robot 10 and the second robot 30 are controlled such that when the manipulator 25 of the first robot 10 moves along the in-forming movement route 51 of the first movement route 50A and performs the forming work in the position from the first step position P2 to the fourth step position P5, the manipulator 45 of the second robot 30 moves along the movement route including the second escape route 53 in the second movement route 50B excluding the in-forming movement route 51. On the other hand, the first robot 10 and the second robot 30 are controlled such that when the manipulator 45 of the second robot 30 moves along the in-forming movement route 51 of the second movement route 50B and performs the forming work in the positions from the first step position P2 to the fourth step position P5, the manipulator 25 of the first robot 10 moves along the movement route including the first diversion route 52 in the first movement route 50A except for the in-forming movement route 51. The first switch-off route 52 of the manipulator 25 of the first robot 10 and the second switch-off route 53 of the manipulator 45 of the second robot 30 are disposed to be spaced apart upward or downward (as shown in the drawing) by a predetermined distance with respect to the in-forming movement route 51, respectively.

The predetermined distances of the first and second switch-off routes 52 and 53 from the in-forming movement route 51 are set as follows. As shown in fig. 6, the distance from the first switch-off route 52 to the in-forming movement route 51 is L1, and the distance from the second switch-off route 53 to the in-forming movement route 51 is L2, respectively. The maximum radii of the manipulators 25 and 45 of the first robot 10 and the second robot 30 are R1 and R2, respectively. To avoid interference between the robot hand 25 of the first robot 10 moving along the first turning-off route 52 and the robot hand 45 of the second robot 30 moving along the in-formation moving route 51, the distance L1 must be larger than R1+ R2 by a certain amount D1. This certain amount D1 is determined to safely avoid interference between the two robots.

Further, similar consideration is made for the case in which the robot hand 25 of the first robot 10 moves along the in-formation movement route 51 and the robot hand 45 of the second robot 30 moves along the second escape route 53, and the distance L2 must be larger than R1+ R2 by a certain amount D2. The amounts of tolerances D1 and D2 may be taken to be substantially the same. By setting the distances L1, L2 from the switch-off routes 52, 53 to the in-forming movement route 51 as described above to avoid interference between the two manipulators, the manipulator 25 of the first robot 10 and the manipulator 45 of the second robot 30 can move without interfering with each other.

The necessity of avoiding interference between the manipulator 25 of the first robot 10 and the manipulator 45 of the second robot 30 is explained above. Furthermore, with two articulated robots, it is necessary to avoid interference between the arms of the two robots. To achieve this, with respect to the first robot 10 and the second robot 30 which are of the articulated type, the movements of the arms constituting the two articulated robots need to be controlled so as to avoid interfering with each other. That is, the movement state of the robot arm (e.g., the swing angle or rotation angle of the arm, the timing of such movement, etc.) should be set to meet the requirement of avoiding interference between the robots during operations performed by the robots to perform roll forging and movements related to roll forging.

With such a roll forging machine 1, the first robot 10 and the second robot 30 can alternately perform forming using the pair of roll dies 4 and 6 that constantly rotate, and thus productivity is improved. For example, when the robot hand 25 of the first robot 10 (or the robot hand 45 of the second robot 30) moves from the receiving position P1 to the first step position P2, the robot hand 45 of the second robot 30 (or the robot hand 25 of the first robot 10) moves from the fourth step position P5 to the carry-out position P6. In this way, the hand 25 of the first robot 10 and the hand 45 of the second robot 30 can move without interfering with each other, and molding is performed by the pair of molds 4 and 6 at all times.

Further, in this roll forging machine 1, the two robots 10 and 30 are operated alternately. Therefore, the time for feeding the material to be formed and the time for unloading the formed article (both lost time for conventional roll forging machines) are not lost time for such roll forging machines 1. This roll forging machine has the following construction: the two manipulators 25 and 45 are arranged in an upper and lower position, respectively (as shown) and interference between the two manipulators 25 and 45 can be avoided so that alternate operation of the two robots 10 and 30 can be achieved. Therefore, the productivity of such a roll forging machine can be improved.

Further, although two sets of roll dies are required in the conventional roll forging machine for improving productivity, the roll forging machine does not require two sets of roll dies. Therefore, such roll forging machine realizes reduction in the cost of manufacturing the die, reduction in the die storage space area, and reduction in the die replacement time, which brings economic advantages.

With the roll forging machine 1 controlled in this manner, the cycle time can be shortened and the temperature variation of the material to be formed can be reduced, so that the improvement of the product quality can be achieved. Further, with such a roll forging machine 1, the rotation can be performed in the same direction so that the direction of the applied load is the same, and therefore the life of the product obtained by the roll forging machine 1 can be improved as compared with the product obtained by a roll forging machine in which the rotation is performed in both one direction and the other direction. Further, continuous forming can be performed using the same roll mold, so that shape variation can be restricted and the quality of products can be improved.

The roll forging method of the roll forging machine is such that roll forging is performed by controlling two robots in the following manner: when the hand of one robot moves along the in-forming movement route, the hand of the other robot moves along a movement route including the first diversion route or the second diversion route other than the in-forming movement route. With this roll forging method, the manipulators 25 and 45 of the two robots alternately perform roll forging (forming with a pair of dies) feeding the material to be formed to the roll dies 4 and 6 without the manipulators interfering with each other, so that improvement in productivity can be achieved.

Although the embodiments of the present invention have been explained above, it goes without saying that the present invention is not limited to only these embodiments. For example, the carrying unit may be an orthogonal coordinate type robot or the like capable of moving in three axis directions. That is, the carrier unit may be a carrier unit capable of controlling the movement of the robot in three dimensions. For configurations in which movement is possible in a direction orthogonal to the horizontal plane in addition to movement in the horizontal plane, such a carrier unit may be configured to: when one robot is in a position to move from the first-step position to the fourth-step position along the in-formation moving route, the other robot may be controlled to move along a moving route (a first turnaround route or a second turnaround route) other than the in-formation moving route and interference of the two robots with each other may be avoided. Further, the articulated robot may be a robot having another configuration or having another number of axes, thus realizing a configuration in which the movement of the robot arm can be controlled in three-dimensional directions.

Further, although the above explanation of the respective embodiments is made for an example of a pair of roller dies having four forming dies formed on each roller die, the pair of roller dies may be roller dies having a plurality of dies (e.g., two or six forming dies) formed thereon. Further, although the embodiments are made with respect to an example in which the forming work is performed by four steps, the forming work may be performed by six steps or two steps or another number of steps as long as the article can be formed.

Further, although the explanation of the embodiments is made with respect to the example of the carrying unit including the suspension type robot (carrying unit) and the floor type robot (carrying unit), a configuration may be considered in which two floor type carrying units are provided on a plane (floor) for mounting the two floor type carrying units with a difference in height. For example, with respect to a first floor plane for mounting one carrier unit, the bottom plane of a pit dug a prescribed amount downward below the first floor plane may be considered a second floor plane for mounting another carrier unit, thus mounting another carrier unit on the mounting plane in the pit.

Claims

1. A roll forging machine comprising:

A pair of roller drive shafts provided to be rotatable on a main body of the roll forging machine, and driven by a driver to rotate the pair of roller drive shafts;

a pair of roller dies provided on the pair of driving shafts, respectively, and having a plurality of forming dies formed thereon with a predetermined interval therebetween;

Characterized in that the carrier unit comprises:

A first robot having a robot arm that moves along a first rectangular movement path including a straight in-forming movement path connecting positions corresponding to the forming positions with the plurality of forming dies and a first turning-off path that is spaced apart from the straight in-forming movement path on one side of the straight in-forming movement path by a predetermined amount; and

A second robot having a manipulator moving along a second rectangular moving route including the straight in-formation moving route and a second turn-off route spaced apart from the straight in-formation moving route on the other side thereof by a predetermined amount, and

Wherein the first robot and the second robot are respectively controlled so that when the manipulator of the first robot moves along the straight in-formation moving route, the manipulator of the second robot moves along a portion of the second rectangular moving route other than the straight in-formation moving route, and when the manipulator of the second robot moves along the straight in-formation moving route, the manipulator of the first robot moves along a portion of the first rectangular moving route other than the straight in-formation moving route.

2. The roll forging machine according to claim 1,

Wherein the receiving position of the material to be formed and the formed article carrying-out position are provided in an extension of the straight in-forming moving route.

3. The roll forging machine according to claim 1 or 2,

Wherein the first robot and the second robot are respectively articulated robots.

4. The roll forging machine according to claim 3,

Wherein each of the first and second robots is disposed in front of the main body of the roll forging machine and includes:

A rotating base which can rotate;

A plurality of arms connected in series to be swung or rotated relative to each other, and one end of the arms connected in series is connected to the rotating base to be capable of swinging, and the robot having a material-to-be-formed-gripping portion is connected to the other end of the arms connected in series.

5. The roll forging machine according to claim 1,

Wherein one of the first robot and the second robot is a floor type robot and the other is a suspension type robot.

6. The roll forging machine according to claim 1,

Wherein the first robot and the second robot are floor-type robots disposed at respective positions having different heights.

7. The roll forging machine according to claim 1,

Wherein the robot hand of the first robot is moved from the receiving position to the mold forming first step position when the robot hand of the second robot is moved from the forming final step position to the formed article carry-out position, and

The robot hand of the second robot moves from the receiving position to the mold forming first step position when the robot hand of the first robot moves from the forming final step position to the formed article carry-out position.

8. A roll forging method using a roll forging machine, the roll forging machine comprising:

A pair of roller dies provided on the pair of driving shafts, respectively, and having a plurality of forming dies formed thereon with a predetermined interval therebetween; and

the carrier unit includes:

A second robot having a manipulator moving along a second rectangular moving route including the straight in-formation moving route and a second turning-off route spaced apart from the straight in-formation moving route on the other side thereof by a predetermined amount;

the roll forging method is characterized in that, when the manipulator of the first robot moves along the straight in-forming movement route, the manipulator of the second robot moves along a portion of the second rectangular movement route other than the straight in-forming movement route,

9. The roll forging method according to claim 8,