PRODUCTION SYSTEM FOR MACHINING WORPIECES

Abstract

Production system for machining workpieces including a transfer comprising receiving and passing on the workpieces for machining from process Station to process Station in a chamber, such as a pressing unit. In the production system, logistical and technological processes are improved by implementing unmanned aerial vehicles (UAV). The UAV is used for process Support monitoring the production process of one of the workpieces or the transfer of the workpieces.

Claims

1-43. (canceled)

44. A production system for machining workpieces (2, 2.1) utilizing a press unit (1.1), with a transfer that encompasses picking up and forwarding the workpieces (2, 2.1) for machining, from process station (1.2) to process station (1.2) in a space (1.4), wherein at least one unmanned aerial vehicle (UAV) (3) is monitoring the production process of one of the workpiece (2, 2.1) or the process support that includes transfer of the at least one workpieces (2, 2.1), wherein the UAV (3) comprises at least one lift (3.6), which when receiving a workpiece (2, 2.1), provides a first lift (3.6.3) that does not effect lift, which is designed to be switched off, and at least a second lift 3.6.2) that effects lift, which is used for the monitoring or a process support of the UAV (3) in the transfer of at least one of the workpieces (2, 2.1) and wherein the at least one lift (3.6) of the UAV (3) is one of a propeller and a jet drive.

45. The production system according to claim 44, wherein the lift (3.6) can be controlled for adjustment away from its vertical axis.

46. The production system according to claim 45, wherein the UAV (3) is equipped with an attachment (3.1) for transporting the workpieces (2, 2.1).

47. The production system according to claim 46, wherein the UAV (3) comprises for the production sequence of the workpieces (2, 2.1) to be monitored at least one or one of the following features or functions: a) a drive that can be controlled in a 3D direction with at least one lift (3.6, 3.6.1, 3.6.2, 3.6.3) for controlling a one-dimensional or multi-dimensional movement in the space (1.4) for implementing a lifting or advancing movement and superposition of directions of movement, dynamic superimposed movements such as lifting and simultaneous horizontal transport or horizontal transport and simultaneous swiveling/tilting of the workpiece (2, 2.1), b) a data network communicating with a central control/regulating device (5) for querying and activating data of the technological or logistical criteria or manufacturing/logistic data at least for the UAV (3) or for one of the workpiece (2, 2.1), a tool (1.1.1), one of the presses (1.1) for controlling the UAV (3) in at least one of the following monitoring processes b1 series production, one-off production or individual production, b2 transfer of semi-finished workpieces (2, 2.1) as special parts and removal of the UAV (3) from a transfer function for maintenance/servicing, b3 energy charging, b4 observing of operations in the machining of the workpieces (2, 2.1), b5 position determination (3.3.1) and centering of the workpieces (2, 2.1).

48. The production system according to claim 47, wherein the UAV (3) is configured for the transfer of the workpieces (2, 2.1) further including at least: a) use instead of a stationary transfer facility, b) a drive configured to control the UAV (3) in the 3D direction with at least one lift (3.6, 3.6.1, 3.6.2, 3.6.3) for controlling a one- or multi-dimensional movement in the space (1.4) to implement a lifting or advance movement and superposition of directions of movement, highly dynamic superimposed movements, c) an arrangement, control, adjustment or switching of at least one of the lifts (3.6, 3.6.1, 3.6.2, 3.6.3) c1 for generating an effective lift in a space (1.4.1) away from the shape of the respective workpiece (2, 2.1), and c2 for the positioned approach/fly-in of the workpiece (2, 2.1) for the purpose of realizing the technology-appropriate transfer, wherein the UAV (3) can be flown with the flattest possible height and with the smallest possible inclination into an area of a tool (1.1.1) of a process station, d) controls and attachment (3.1) for transferring the workpiece to be formed or already formed by attachment points (2.2) on the workpiece (2, 2.1) for a process-safe movement sequence in the space (1.4) and away from or outside the space (1.4), while obeying the laws of movement, e) a data group communicating with a central control/regulating device (5) for the transfer to query and activate data of the technological or logistical criteria or production/logistic data at least for the UAV (3) or for the workpiece (2, 2.1) or for the tool (1.1.1) or for the press, transfer press or press line (1.1) for controlling the UAV (3) for the transfer in at least one of the following transfer sequences e1 series production, one-off production or individual production, e2 transfer of semi-finished workpieces as special parts, e3 removal of the UAV from a transfer function for maintenance/repair, e4 energy charging, e5 with the attachment (3.1), e6 for operations in machining the workpiece (2, 2.1), e7 determining position and centering the workpiece (2, 2.1), e8 surface treatment of the workpiece (2, 2.1).

49. The production system according to claim 48, wherein the UAV (3) a) takes over the workpiece (2, 2.1) from a prefabricating or first process station (1.2.1), transfers the workpiece (2, 2.1) via at least one subsequent or up to an n-th process station (1.2.2) of the process stations (1.2.1, 1.2.2) and deposits it, and b) returns to the first process station (1.2.1) for each repeatable transfer and technological sequence, picks up a new workpiece (2, 2.1) and accompanies the process in the process stations (1.2.1, 1.2.2) and deposits the workpiece (2, 2.1), wherein steps a) and b) are included in a first flight pattern (F1) of the UAV (3) or the group of UAVs (3) and can be monitored.

50. The production system according to claim 49, wherein a) for each transfer process, a first UAV (3) or a first group of UAVs (3) is assigned from the first process station (1.2.1) to the next process station (1.2.2) to the machining of the workpiece (2, 2.1) to be performed, b) the workpiece (2, 2.1) is picked up/taken over in a first of the process stations (1.2, 1.2.1) from the first UAV or the first group of UAVs (3) and then delivered/handed over to the next process station (1.2), where the workpiece (2, 2.1) is again picked up/taken over by at least one UAV or a group of further to n-th UAVs (3) and delivered/handed over to one of the following up to the n-th process station (1.2.2), c) a new up to n-th workpiece (2, 2.1) is transferred analogous to the sequence of steps b), and d) each transfer process of the first UAV or the first to n-th group of UAVs (3) includes a second flight pattern (F2) and can be monitored, e) wherein each UAV or each group of UAVs (3) picks up/takes over and releases the workpiece (2, 2.1) specifically for the transport between two technological operations, and wherein the special technological operations and the corresponding transfer logistics of the UAV or the group of UAVs (3) are monitored in each circulating second flight pattern (F2), wherein the group of UAVs (3) is available for at least some of the process stations (1.2.1, 1.2.2).

51. The production system according to claim 50, wherein the workpiece (2, 2.1) is deposited in an intermediate storage facility (2.3).

52. The production system according to claim 50, wherein in the transfer from process station (1.2) to process station (1.2) in the space (1.4), one of the process stations (1.2, 1.2.1, 1.2.2) is a final stage of the machining or the start of further machining or processing of the workpiece (2, 2.1).

53. The production system according to claim 50, wherein a path measuring/positioning system (1.3) corresponding to the control/regulating device (5) and having a second data memory and computer is assigned to each (1.1) for requesting a function to be carried out by a UAV (3) specifically for the technological operation.

54. The production system according to claim 50, wherein an information system is integrated in the first data memory (3.3) in the respective UAV (3), enabling the UAV (3) to a) identify workpieces (2, 2.1) that were not machined according to position, rolling direction or quality, b) record data from presses (1.1), and c) execute or derive control signals for technological measures.

55. The production system according to claim 50, wherein a multicity (3.5) of UAVs (3) with the control/regulating device (5) controlling the multiplicity of pool (3.5) is formed in the press (1), with which at least one UAV (3) can be a) programmed with at least one of the signals for executing the functions corresponding to a respective process station (1.2, 1.2.1, 1.2.2), including forming/pressing processes and process stages leading back to cutting processes, b) activated for providing i. maintenance tools, ii. a non-positive or positive attachment (3.1) iii. transport unit, such as traverses, iv. tooling for tool changes v. creating actions for workpieces (2, 2.1) and tools (1.1.1), vi. heating by induction, cooling with a fan, c) queried for determining the type or specifics i. of its drive, ii. of the drive's communication link, iii. shape of the picked-up workpiece (2, 2.1) (2D, 3D), iv. a material type of the workpiece (2, 2.1), v. electro-physical properties, including one of non-ferrous, magnetic/magnetizable, non-metallic property of the workpiece (2, 2.1), d) availability can be queried depending on i. flight operations (free/tied), ii. energy generation/supply/conversion, iii. actions to be performed on workpieces (2, 2.1) and tools (1.1.1).

56. The production system according to claim 55, wherein the UAV (3) incudes optical equipment (3.2) and 3D camera and an evaluation unit with a controller (3.3) with a first data memory with a file and a computer for observing processes of the machining of the workpieces (2, 2.1), parts control and transmission of signals.

57. The production system according to claim 56, wherein data from spatial coordinates of the UAV (3) are captured externally by one of an optical device, a ultrasound. an electronically, and the movement of the UAV (3) is performed in a controlled or in regulated manner by specifying said data.

58. The production system according to claim 57, wherein the UAV (3) comprises a self-determining or self-measuring device for determining a position (3.3.1) by using reference points (coordinates/scales) in the space (1.4).

59. The production system according to claim 58, wherein the UAV (3) is equipped with a tracking device, identifying the workpiece (2, 2.1) and for recognizing logistical/technological operations.

60. The production system according to claim 59, wherein provisioning of a number n of operational UAVs (3) that are controlled by the central control/regulating device (5), and is adapted to a number of press strokes depending on the energy consumption and the energy charging time of the UAV (3).

61. The production system according to claim 57, wherein both data relating to safety aspects for the individual UAV (3) and data relating to a machine, workpiece and personal date can be functionally/program-linked in the control/regulating device (5) in such a way that a) several UAVs (3), each having a workpiece (2, 2.1), follow the technology-dependent commands for carrying out the actions (3D movements, changes in position) of the workpiece (2, 2.1) for lifting/lowering, transporting, for rotary movements such as swiveling, tilting, rotating, or turning, including the actions of heating the workpiece (2) by induction, cooling the workpiece (2, 2.1) with a fan, or b) these actions performed partially superimposed, simultaneously, and can be controlled/regulated according to the performance data of these actions machined by the control/regulating device (5) according to the maximum possible performance data, or c) a learning program can be generated which can be transferred and installed in an external (press) plant (1), or which can be used in place of manually practiced or learned movement sequences, or d) several UAVs (3) or parts of different UAVs (3) can be coupled with and decoupled from one another, with or without using of common lifting elements (3.1).

62. The production system according to claim 53, wherein a database is set up in the control/regulating device (5) which has a file comprising at least one type of the following data: a) data on the geographical altitude and location of the press plant (1), the position of the presses, transfer presses or press lines (1.1), b) data regarding the geometry (2D, 3D) and technological operations of the workpiece to be picked up and reshaped after cutting (2, 2.1) up to the finished component, c) data on the metallurgical or non-metallurgical properties of the material of the workpiece (2, 2.1), d) data for identifying the workpiece (2, 2.1) with for example barcodes, wherein the data are implemented as e) as (machine) data of the individual process stations (1.2, 1.2.1, 1.2.2) of the respective press, transfer press or press line (1.1), f) as data of a tool change, wherein a part-specific tooling can be placed directly on the tool (1.1.1), g) as data of the pool (3.5) with several UAVs (3), and, on the one hand, control the UAV (3) and, on the other hand, can be called up by the UAV (3) and can monitor or act on the logistical and technological process.

63. The production system according to claim 62 wherein the UAV (3) can be equipped with measuring means for the detection of rejects and special situations in the onboard UAV (3) information system with sensors for data recognition and component tracking.

64. The production system according to claim 44, wherein the UAV (3) in the controllable first data memory (3.3) comprises a file with at least one of the following criteria: a) a position accompanying the workpiece (2) or a position assigned to the process station/press station (1.2, 1.2.1, 1.2.2), b) the type of lift means (3.6) implemented as a propeller, jet or turbine, c) the energy supply/supply being integrated/stored, suppliable, convertible, d) the mode of operation as free-flying or tied up, e) the attachment means (3.1) and attachment points (2.2) for the transfer, f) separable information about respective technological operations carried out or to be carried out, with respect to the stacking/storage situation, to quality control and the resulting measures such as separation of parts, g) performance data of the UAV (3), including its geographical altitude and location of the press plant (1), h) callable reference programs of machining processes.

65. The production system according to claim 44, wherein an identification system of each workpiece (2, 2.1) that can be read by scanners or cameras with appropriate software and further machined electronically commensurate with the technology.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0192] The invention is described with reference to examples and in the following figures.

[0193] These show in

[0194] FIG. 1 a diagram of a press plant 1 as a flow image with press, transfer press or press line 1.1, with a UAV 3 receiving a new workpiece 2 from a process station 1.2 with a first process station 1.2.1 to a process station 1.2 with an n-th process station 1.2.2 accompanying a workpiece 2 to be machined, ending with the finished formed component and returning to the first process station 1.2.1, while repeating the process, according to the first aspect of the production system according to the invention,

[0195] FIG. 2 a diagram of the process flow in the press plant 1 as a flow image with press, transfer press or press line 1.1, with a UAV 3 provided for the respective process station 1.2, which is specifically assigned to the technological operation such as the forming stage, receiving and transferring the workpiece 2, according to the second aspect of the production system according to the invention,

[0196] FIG. 3 schematic diagrams of a path measuring/positioning system associated with each press, transfer press or press line 1.1 with a second data memory and computer 1.3 for requesting a function to be carried out by a UAV 3 specifically for the technological operation according to the third aspect of the production system according to the invention,

[0197] FIG. 4 schematic diagrams of a first data memory 3.3 integrated in a UAV 3 with a file and a computer 3.3 for carrying out operational measures of the UAV 3 in accordance with the fourth aspect of the production system according to the invention,

[0198] FIG. 5.1 a schematic diagram of the system of a control/regulating device 5 for a pool 3.5 of several UAVs 3 in the press plant 1, corresponding to the fifth aspect of the production system according to the invention,

[0199] FIG. 5.2 a diagram according to FIG. 5.1, shown as a complex control and regulation system,

[0200] FIG. 6 schematic details for the transport of parts of the workpiece 2.1 relating to [0201] an arrangement with adjustable 3.6.1, couplable 3.6.2, switchable 3.6.3 lift means 3.6 of the UAV 3, [0202] the attachment means 3.1 of the UAV 3, and [0203] the attachment points 2.2 on the workpiece 2 as a half-finished passenger car door 2.1, and

[0204] FIG. 7 a schematic diagram of the UAV 3 as a drive for a joint kinematics 3.8, including various mechanical elements 3.8.1 and a first guide means 3.7.

EXAMPLES FOR CARRYING OUT THE INVENTION

[0205] The invention will now be explained with reference to FIGS. 1 to 7, from which features and schematized, logistically and technologically linked sequences for workpieces 2, 2.1 to be machined and formed in a closed space 1.4 of an unillustrated press plant 1 with reference to a complex production system.

[0206] FIG. 1 shows in the plane of view designated with a) an unlabeled sheet-metal strip coil, an unlabeled strip feed and a cutting press 1.1 as a continuously operable process station 1.2. Thereafter, workpieces 2 are cut out by the cutting press 1.1—in this case a first process station 1.2.1—as so-called blanks for further machining such as forming.

[0207] According to the invention, at least one UAV 3 is used as a transfer device for the workpieces 2, 2.1 to further process stations 1.2, ending with the so-called semi-finished component such as a passenger car door 2.1 (FIG. 6).

[0208] This respective UAV 3 has for the very complex technological and logistical operations for the forming machining of the workpieces 2, 2.1 the features or functions described below with reference to FIGS. 3 to 6.

[0209] Accordingly, each UAV includes 3—similar to a helicopter/drone controllable in 3D directions—the technical means, which can be seen in more detail in FIGS. 4, 5.1, 5.2 and 6 and which enable control of a 3D movement in space 1.4, a process area or a production hall of the press plant 1. Therefore, according to FIG. 6, an arrangement, control, adjustment or switching of lift means 3.6 (propellers, jets) is provided for the UAV 3, which [0210] ensures the generation of an effective lift commensurate with the laws of aerodynamics—also in a space 1.4.1 facing away from the shape of the respective workpiece 2, 2.1, and thus [0211] secures, for implementing the transfer, a positioned approach/fly-in of the workpiece 2, 2.1 to a tool 1.1.1.

[0212] The UAV 3 should be flown into an area of the tool 1.1.1 of the process station 1.2 while having the least possible overall height and the smallest possible inclination. Accordingly, the overall dimensions of the employed UAV 3 can be determined in an optimized manner in accordance with the logistical and technological conditions of a press plant 1 or of the presses 1.1.

[0213] FIG. 3, FIG. 4, FIG. 5.1, FIG. 5.2 and FIG. 6 illustrate means for control and attachment means 3.1 of the transfer for each of the formed or to be formed workpieces 2, 2.1 (according to FIG. 1 and FIG. 2).

[0214] The sequence of movements in the transfer system according to the invention in the space 1.4 as a transfer space (not shown) and outside thereof is illustrated correspondingly and symbolically in FIG. 1. The movement is governed by the laws of motion and is always controlled. The attachment means 3.1 of the UAV 3 are also controlled in the same way and correspond to the attachment points 2.2 of the workpiece 2, 2.1, as can be seen in more detail in FIG. 6.

[0215] The production system with monitoring and transfer of the workpieces 2, 2.1 includes a data network for querying and activating data for the UAV 3, the workpiece 2, 2.1, the tool 1.1.1 and the respective press 1.1. This data network includes for communication a central control/regulating device 5 shown in FIG. 3, FIG. 5.1 and FIG. 5.2. In this way, all the technological and logistical criteria as well as production/logistics data can be processed and controlled, as required for series production, individual production, single production, the introduction of semi-finished special parts of the workpiece 2, 2.1, energy charging of the UAV 3, the attachment means 3.1, removal for maintenance/repair from a transfer function of the UAV 3, observation of machining operations and position determination 3.3.1 and centering of the workpiece 2, 2.1 while supporting the process in the production system.

[0216] The UAV 3 is equipped for implementing a forward feed movement and a superposition of movement directions and highly dynamic superimposed movements, such as lifting and simultaneously transporting the workpiece 2, 2.1 horizontally, or transporting the workpiece 2, 2.1 horizontally and at the same time pivoting/tilting the workpiece 2, 2.1 with a controllable rotor axis 3.1.1 shown in FIG. 6, in this example operated with rotor blades 3.1.3 (FIG. 3, FIG. 4, FIG. 6). Horizontal movements can thus be realized, with the horizontal axis of individual rotor blades 3.1.3 being adjustable. If the employed presses 1 offer sufficient transfer space in the space 1.4, the UAV 3 can be equipped with rotor blades 3.1.3 operating on top of one another, despite the greater overall height, for the purpose of transferring heavy workpieces 2, 2.1.

[0217] A first logistical-technological aspect can be inferred from the view planes a), b), c) in FIG. 1 according to this technologically and logistically linkable production system according to the invention of process monitoring and transferring the workpieces 2, 2.1. The UAV 3 accompanies the transfer the workpiece 2 to be machined as a blank received in the view plane a) from a first process station 1.2.1 to at least one further process station, such as the n-th process station 1.2.2. The UAV 3 then returns to the first process station 1.2.1, picks up a new workpiece 2 and runs at least through parts of the process stations 1.2.1, 1.2.2, and then repeats these process stations 1.2, 1.2.1, 1.2.2, as schematically shown in a first, quasi-circulating and process-monitoring flight pattern F1.

[0218] Thus, a single UAV 3 transfers the workpiece 2, 2.1, taking over from the pre-machining first process station 1.2.1, via at least one subsequent or up to the n-th process station 1.2.2 of the process stations 1.2.1, 1.2.2, and then places it in an interim storage facility 2.3. For each transfer and technological sequence to be repeated, the UAV 3 returns to the first process station 1.2.1, picks up a new workpiece 2, 2.1 and accompanies it once more through the process stations 1.2.1, 1.2.2 up to the intermediate storage facility 2.3. Each process sequence is recorded with the first flight pattern F1 of the single UAV 3 and can be monitored.

[0219] The process station 1.2 is schematically illustrated in the view plane b) as a transfer press 1.1, and in the view plane c) as a press line 1.1.

[0220] In the respective interim storage facility 2.3, cut blanks 2 (view plane a)) and machined and reshaped workpieces 2.1 are stacked for transfer to further process stations 1.2 by means of the UAV 3 or as a semi-finished component for the shell of a product.

[0221] According to this first aspect of the invention, the aforementioned logistical-technological processes or at least parts of the processes can also be taken over by a single group of several UAVs 3 instead of the aforementioned UAV 3.

[0222] Alternatively and differently, FIG. 2 shows a second logistical-technological aspect of the system according to the invention. In this case, a UAV 3 is provided for a respective process station 1.2, 1.2.1, 1.2.2 of the presses 1.1, which picks up and releases the workpiece 2, 2.1 specifically for a technological operation of the process stations 1.2, 1.2.1, 1.2.2.

[0223] This special transfer logistics of the UAV 3, corresponding to the respective technological operation, such as pick-up, transport, delivery and return, is shown in a second, quasi-circulating and process-monitoring symbolic flight pattern F2. Thus, a UAV 3, which is specifically responsible for the transfer logistics between two successive process stations 1.2, 1.2.1, 1.2.2, is provided for each process station 1.2, 1.2.1, 1.2.2, wherein the first or previous technological process step and the corresponding transfer logistics of the UAV 3 to the second or following technological process step can be monitored by the circulating second flight pattern F2.

[0224] Accordingly, this second logistical-technological aspect is distinguishable from the first logistical-technological aspect by the following characteristics: [0225] a) one respective UAV 3 is assigned to each transfer process of the technological machining of the workpiece 2, 2.1 to be carried out from the first process station 1.2.1 to the n-th process station 1.2.2, [0226] b) the workpiece 2, 2.1 is picked up/taken over by a first UAV 3 in a first of the process stations 1.2, 1.2.1, 1.2.2 and then delivered/transferred to the next process station 1.2.1, and is therefrom again picked up/taken over by a second UAV, such as other UAVs up to the n-th UAV 3, and handed over to one of the following process stations, up to n-th process station 1.2.2, and finally stored in the interim storage facility 2.3, [0227] c) a new workpiece 2, 2.1, up to n-th workpiece, is transferred analogously to the sequence of steps b), and [0228] d) each transfer and technological process of the first through the n-th UAV 3 is monitored with a dedicated second flight pattern F2.

[0229] Following the process flow of FIG. 2 from the unlabeled sheet-metal strip coil via the unlabeled strip feed to the cutting press 1.1, workpieces 2 are prefabricated as blanks in the continuously operable first process station 1.2.1, picked up by the UAV 3 that is specifically assigned to this operation and repeats this transfer logistics, and deposited at the first intermediate storage facility 2.3 for blanks 2.

[0230] Each specially assigned UAV 3 takes over the pick-up/takeover/delivery of the workpiece 2 in one of the following technological operations, such as forming stages in the respective process stations 1.2 up to the n-th process station 1.2.2.

[0231] As a result of this process according to the invention, machined and formed workpieces 2 are stacked in the second intermediate storage facility 2.3 as semi-finished components for constructing the shell of a product.

[0232] According to this second aspect of the invention, the aforementioned logistical-technological processes, at least for parts of the processes, can also be taken over by a first to n-th group of several UAVs 3, instead of the respective first to n-th UAV 3.

[0233] FIG. 3 schematically outlines a third logistical-technological aspect of the system according to the invention. Herein, an electronic path measuring/positioning system 1.3 corresponding to the central control/regulating device 5 with a second data memory and computer is assigned to each individual press, transfer press or press line 1.1, and is used equally [0234] both in the first and/or second logistical-technological aspect, [0235] as well as in the context of the following.

[0236] In this way, data for a function to be executed by the UAV 3 specifically for the technological operation can be communicated from each individual press, transfer press or press line 1.1 as requested, and activated.

[0237] The electronic path measuring/positioning system 1.3 for feeding the workpiece 2, 2.1 with the correct position and orientation is in this example operatively connected to a centering system, which includes, on the one hand, according to FIG. 7, a first guide means 3.7 on the UAV 3 and, on the other hand, an unillustrated stationary second guide means which is integrated, for example, on the tool 1.1.1. The centering system thus acts as an advantageous and functionally synergetic combination of electronic and mechanical positioning.

[0238] FIG. 7 shows a process-related integrated mechanical transfer device that is essential to the invention and embodied on the UAV 3 operated with rotor blades 3.1.3 of the rotor axis 3.1.1. Their movement in space 1.4 is implemented with a control element 3.3.4 by way of a force-controlled, multi-dimensionally stabilizable joint kinematics 3.8, which can be coupled via mechanical elements 3.8.1, with the attachment means 3.1 and attachment elements 3.1.2 shown in FIGS. 5.1 and 5.2 for receiving and depositing the workpiece 2, 2.1 operating like a rod kinematics.

[0239] It should be emphasized that the path measuring/positioning system 1.3, the centering system and the joint kinematics 3.8 are to be regarded as being independent of one another.

[0240] With the joint kinematics 3.8, the UAV 3 is advantageously used as a pure drive means for the mechanical transfer system and drives the light-weight rod kinematics. As a result, such a transfer system is different from the transfer devices described as prior art at the beginning because it is much lighter, structurally smaller and less expensive, especially since there are no driving forces and torques to be transmitted.

[0241] In this context, according to FIG. 3, reference points (coordinates/scales) for the UAV 3 circulating, for example, along the flight pattern F2 are provided in the space 1.4 (indicated according to FIG. 1) and self-determining or self-measuring devices for position determination 3.3.1 or for parking or switching off by means of a safety control 3.3.2.

[0242] FIG. 4 shows a fourth logistical-technological aspect of the system, with an information system integrated in the respective UAV 3 in a first data memory 3.3.

[0243] This UAV 3 detects—with functional process monitoring—workpieces 2 that were not machined in accordance with the correct position, rolling direction and quality, records external information such as press data, and executes control signals for technological measures. For this purpose, measuring devices 3.3.3 such as sensors illustrated on the left side of FIG. 4, and/or optical devices 3.2 such as a camera illustrated on the right side of FIG. 4 are provided.

[0244] The measuring devices 3.3.3 with sensors are also used to recognize data from a reject and in special situations. The optical devices, such as, for example, a 3D camera 3.2, are connected for evaluation to the first data memory 3.3 with the file and computer. In this way, the processes related to the machining of workpieces 2, 2.1 can be observed and control signals can be outputted. At the same time, a UAV 3's onboard information system for data recognition as well as positioning is realized, also communicating with the electronic path measuring/positioning system 1.3 according to FIG. 3.

[0245] In addition, this onboard information system of the respective UAV 3 can communicate those particular data in the controllable first data memory 3.3 that relate to [0246] coordinating the workpiece 2, 2.1 or a position corresponding to the process station/press station 1.2, 1.2.1, 1.2.2, [0247] the type of propulsion or lift means 3.6, such as propeller, jets, turbine, [0248] the type of energy supply/feed, such as integrated/stored, conveyable, changeable, [0249] the operating mode, such as free-flying or tied down, [0250] transport/attachment means 3.1, such as traverse, non-positive/positive (suction cups, gripping pliers), multiple/simple receptacle, [0251] separable information about technological operations to be carried out and previously carried out, stacking/storage situation, quality control and any measures resulting therefrom, separation of parts, also by using barcodes, [0252] recording, machining and outputting performance data of the UAV 3, including data relating to a geographical altitude, such as the altitude of the press plant 1, and retrievable reference programs of machining processes.

[0253] Lastly, FIGS. 5.1 and 5.2 sketch in form of individual schematic diagrams, a technologically and logistically significant fifth aspect of the production system according to the invention.

[0254] According to FIG. 5.1, the unillustrated press plant 1 includes a pool 3.5 of several UAVs 3, the control/regulating device 5 that controls, i.e. functionally monitors, this pool 3.5, and a flight simulator 4.

[0255] With the control/regulating device 5, the respective UAV 3 is controlled in the interrogation mode with the following signals for [0256] carrying out the required functions, programmed according to a respective process station 1.2, 1.2.1, 1.2.2, including forming/pressing processes and return process steps, for example to cutting processes; [0257] equipping with the necessary attachment means 3.1 and tools for maintenance by means of [0258] force-fit or form-fit mountings, [0259] transport means, such as traverses and the like, [0260] tooling for changing tools 1.1.1, [0261] performing actions on workpieces 2, 2.1 and tools 1.1.1, such as heating by induction, cooling with a fan; [0262] determining the type or specifics of its drive, its communication link (free or tied down), a shape (2D, 3D) of the received workpiece 2, 2.1; [0263] making provisions according to the type of flight operation (free/tied down), energy generation/supply/conversion, other actions.

[0264] With the production system that is logistically and technologically linked in this way and operates according to the invention as a process monitoring and transfer system, previously unprofitable secondary processes can be integrated so efficiently that from the pool 3.5, for example by using only one UAV 3, the scrap generated in the machining system for workpieces 2, 2.1 can be controllably, “operatively flown out”.

[0265] Furthermore, a UAV 3 can be powered by batteries, capacitors, fuel cells or similar energy supply or charged—also when not airborne, like driving on a belt—or diverted from a function (e.g. flight pattern F2 in FIG. 2) for necessary maintenance/repair, and a UAV 3 available from the pool 3.5 can be inserted in a process-safe manner for a controlled return to a process station 1.2, 1.2.1, 1.2.2, for example according to the flight pattern F1 in FIG. 1.

[0266] The UAV 3 is equipped [0267] for a monitorable operational status with reporting of external data and onboard status data such as battery status for energy charging or for attachment means such as a vacuum suction device to the central control/regulating device 5, and [0268] with optics such as camera 3.2 for evaluation by means of the first data memory with file and computer 3.3 for observing processes of the machining of workpieces 2, 2.1, parts control and transmission of control signals.

[0269] In principle, every controlled UAV 3 can be measured externally optically, by ultrasound or remotely.

[0270] In addition, the respective UAV 3 is equipped with means for component tracking, identification and recognition of any logistical and/or technological operations, for which purpose a barcode system (or similar system) that can be read by scanners or cameras with appropriate software and electronically machined is provided on each workpiece 2, 2.1.

[0271] The production system according to the invention thus ensures that during the ongoing work processes/operations on the workpieces 2, 2.1 or the operations of a press 1.1 on a workpiece 2, 2.1, a UAV 3 that is parked away from the press 1.1 can be supplied with energy or charged and reinserted.

[0272] Overall, the production system, with the provision of a number n of operational UAVs 3 that are controlled by the central control/regulating device 5, synergistically supports the actual press operation in such a way that this number can always be adapted to the n press strokes or can be extended by n press strokes depending on the (energy) charging time, so that the UAV 3 is technologically available or reusable for every o-th press stroke.

[0273] FIG. 5.1 shows symbolically in the functional connection with the control/regulating device 5, the pool 3.5 and the flight simulator 4 that the respective UAV 3 [0274] in view a), can be used as a sacrificial UAV 3.4 which may be discarded, if necessary, in dangerous process areas as a calculated loss object; [0275] in view b), can be equipped for attachment means 3.1 such as vacuum suction cups (with unillustrated) drivable pumps, air tanks for overpressure or vacuum, for transporting workpieces 2, 2.1 or for maintenance tools; [0276] in views c) and d), can be used as a UAV 3 that is permanently connected via a line, such as cable and/or hose 3.3.5, for the purpose of external energy supply or is equipped with e-magnetic attachment means 3.1 or rechargeable with energy in flight.

[0277] FIG. 5.2 illustrates the invention as a complex control system integrated in the technological and logistical processes of the press plant 1 according to views a) to d), specifically in cooperation with the analog functions of the UAV 3 previously captured in FIG. 5.1.

[0278] Accordingly, this control and regulation system includes with [0279] the block according to view a) the use of the sacrificial UAV 3.4 in dangerous process areas as a calculated loss object, [0280] the block according to view b), the use of the attachment means 3.1 with attachment elements 3.1.2 and control of the rotor axis 3.1.1, the rotor blades 3.1.2 by means of control element 3.3.4, [0281] the blocks according to views c) and d), the control of a UAV 3 that is connected via a line, such as cable and/or hose 3.3.5, for the purpose of external energy supply, or that is equipped with e-magnetic attachment means 3.1 or chargeable with energy in free flight, wherein the UAV 3 is available from the pool 3.5 and is monitorable/trackable using flight simulator 4.

[0282] In general, the control/regulating device 5 links and is able to communicate functional/program-related data relating to safety aspects for the individual UAV 3 as well as machine, workpiece and personal data for executing the following functions essential to the invention: [0283] several UAV 3, each with a workpiece 2, 2.1, follow the technology-related controlled commands to carry out the actions (3D movements, changes in position) of the workpiece 2, 2.1, such as lifting/lowering (z-axis), transporting (y-axis), swiveling, tilting, rotating, turning, including actions such as inductive heating of workpiece 2, 2.1 or cooling of workpiece 2, 2.1 by means of a fan. [0284] control/regulation of the partially superimposed or simultaneously executed actions with the performance data processed by the control/regulating device 5 and the maximum possible performance data in the press plant 1, [0285] additional generation of a learning program, which can be used for later processes and is repeatable, transferable and installable in an external plant or used in lieu of manually practiced or learned movement sequences.

[0286] The database set up for this in the control/regulating device 5 also includes a file of the following data: [0287] data of the geographical altitude and location of the press plant 1, the position of the presses, transfer presses or press lines 1.1 in the space 1.4, [0288] data of the geometry (2D/3D shape) and technological operations of the workpiece 2 to be picked up and formed after being cut up, ending with the finished component such as passenger car door 2.1, (machine) data of the individual process stations 1.2, 1.2.1, 1.2.2 of the respective press, transfer press or press line 1.1, data of a change of the tool 1.1.1, and data of the pool 3.5 with several UAV 3 and barcode or similar data.

[0289] These data are used, on the one hand, to control the UAV 3 and, on the other hand, can be called up by the UAV 3.

[0290] FIG. 6 shows details according to the invention of the parts transport of the workpiece 2 in form of a car door 2.1 typical for a press 1.

[0291] In this case, the workpiece 2.1, which is machined and formed following the cutting and forming operations and which is to be transferred by means of the process-monitoring UAV 3, is manufactured in accordance with the planned logistical and technological processes, finally be provided as a passenger car door 2.1 for a passenger car shell according to the production system according to the invention, in particular with the complexity of the combinable solution variants, including a surface treatment of the workpiece 2, 2.1, and the first or second and third to fifth logistical-technological aspects described above.

[0292] According to the features inferred from FIG. 6, the UAV 3 can also be operated in the embodiments with [0293] a lift means 3.6 (image, center left), or [0294] several lift means 3.6 (image, top left) and in this case by using propellers such as rotor blades 3.1.3.

[0295] Depending on the execution and the required 2D or 3D movement sequences, the respective UAVs 3 are equipped with attachment means 3.1 (FIG. 5.1), which are attached at exposed, balanced and predeterminable attachment points 2.2 of the passenger car door 2.1 and transfer/transport the same up to the second intermediate storage facility 2.3 (FIG. 1, FIG. 2).

[0296] According to FIG. 6, in the upper view plane with the (unlabeled) first attachment position, starting on the left, up to the (unlabeled) fifth attachment position, the following examples of attachment types of the UAV 3 for transferring, such as picking up and putting down the car door 2.1, are possible for this purpose: [0297] four UAVs 3, each equipped with several lift means 3.6, are attached at predetermined, balanced attachment points 2.2, [0298] four UAVs 3, each equipped with a lift means 3.6, are attached at the designated receiving points 2.2, wherein the UAVs 3—as indicated in the form of a cross—are connected mechanically (traverse) or via electronical communication, [0299] two UAVs 3 each with several lift means 3.6 at the end of an indicated traverse with 2 cross members are attached at four attachment points 2.2 (third to fifth attachment positions).

[0300] FIG. 6 also shows the UAVs 3 having attachment elements 3.1.2 in the center of the image [0301] on the left-hand side with a disconnectable lift means 3.6.3, and [0302] on the right-hand side, the lift means 3.6.1 adjustable with the rotor axis 3.1.1.

[0303] On left-hand side of the lower image plane, a point-shaped attachment of the UAV 3 with the lift means 3.6 on the car door 2.1 for the lift-preserving transfer in a space 1.4.1 away from the shape of the passenger car door 2.1 is illustrated and easily visible.

[0304] Likewise, as illustrated and easily visible on the right-hand side of the lower image plane, the passenger car door 2.1 or a differently formed or machined workpiece 2, 2.1, depending on the geometric design and the technological machining steps, can be transferred in the correct position commensurate with the controlled technological and logistical 2D or 3D movement sequences according to FIG. 5.2 in the space 1.4 of the press plant 1 by the control and regulating device 5 and adjustable 3.6.1, couplable 3.6.2 or switchable 3.6.3 lift means 3.6 of the UAV 3.

[0305] The use of any UAV 3 in the space, process area, working plant 1.4 of the press plant 1, including the lifting positions at the lifting points 2.2 of the workpiece 2, 2.1, are to be planned and implemented in accordance with the logistics and design so that the lift means 3.6, such as propeller, jet maintain lift in accordance with the aerodynamic lift laws, but also can be switched off. This is shown symbolically, for example, as a detail in FIG. 6, center image, and lower left and right images.

[0306] In an embodiment of the second logistical aspect of the system according to the invention, which is shown in FIG. 2, according to which one UAV (or a group of several UAVs) 3 is provided to a respective process station 1.2, 1.2.1, 1.2.2 of the presses 1.1, which especially for a technological operation of the process stations 1.2, 1.2.1, 1.2.2 picks up and releases the workpiece 2, 2.1, the following should be emphasized in more detail.

[0307] This special transfer logistics of the UAV 3, corresponding to the respective technological operation, such as pick-up, transport, delivery and return, is shown in a second, quasi-circulating and process-monitoring symbolic flight pattern F2.

[0308] Assuming that a UAV 3 with several rotor blades 3.1.3 has attachment means 3.1 such as suction cups, several UAV 3 are provided for transporting a workpiece 2, 2.1. When the UAV 3 is idling or returning, i.e. when no workpiece 2, 2.1 is being transported, all rotor blades 3.1.3 of the UAV 3 are functional and provide lift when monitored and operated and/or controlled by the central control/regulating device 5.

[0309] When several UAVs 3 are positioned at attachment points 2.2 for the joint transport of one workpiece 2, 2.1, individual rotor blades 3.1.3 of different UAV 3 may not provide effective lift, when they act, due to their positioning, aerodynamically against workpiece 2, 2.1, for example against surfaces of the passenger car door 2.1, and thus do not generate any lift. In this situation, these rotor blades 3.1.3 that do not contribute to the lift are according to the invention switched off in a controlled manner, and rotor blades 3.1.3 of different UAVs 3 positioned so as to provide effective lift are functionally combined with one another as a temporarily controlled group of several UAVs 3 for transporting the workpiece 2, 2.

[0310] After the workpiece 2, 2.1 has been deposited at a next process station 1.2, 1.2.1, 1.2.2, this group of rotor blades 3.1.3 effecting the lift is disbanded again in a controlled manner. The rotor blades 3.1.3 thus cooperate again within the respective UAVs 3, and the UAVs 3 each leave the process area in the space 1.4 individually, with their rotor blades 3.1.3 providing full effective lift.

[0311] The press 1.1 executing the work process then performs a stroke. The UAV 3 then return to the already formed or to the next workpiece 2, 2.1 to be able to take up the ongoing transport in the transfer, with this process being repeated.

[0312] With regard to the future implementation of the production system, the following logistically and technologically improved linkage of features of the invention is essential: [0313] The correct position- and orientation-dependent feed and removal of the workpiece 2, 2.1 in the process stations 1.2, 1.2.1, 1.2.2 with the respective cutting and forming tools 1.1.1 that carry out the technological operations and have each one upper tool and one lower tool, from which the workpiece 2, 2.1 must be removed after the work step. [0314] The path measuring/positioning system 1.3 communicating with each single press, transfer press or press line 1.1 and with the central control/regulating device 5 having the second data storage device and computer for requirements of the function to be carried out by the UAV 3 specifically for the technological operation. [0315] The centering system integrated with path measuring/positioning system 1.3 for feeding the workpiece 2, 2.1 with the correct position and orientation, which ensures a smooth insertion of the workpiece 2, 2.1 at an exact position, on the one hand, via the first guide means 3.7 and, on the other hand, via the second guide means which is stationary with respect to the tool 1.1.1.

Commercial Applicability

[0316] The process-monitoring production system disclosed according to the invention for workpieces to be machined with their transfer by means of inexpensive, technology-oriented UAV (Unmanned Aerial Vehicle) offers a significant potential of technological improvements, especially in press plants to be planned in the future, due to the elimination of installation space and of expensive transfer facilities, compared to the present state of the art, where unmanned aerial vehicles/objects have a high level of equipment in terms of mechanical and electronic means as well as integrated data machining, but have only taken over logistical functions in processes in production systems.

LIST OF REFERENCE SYMBOLS

[0317] 1 press plant [0318] 1.1 press, cutting press, transfer press, press line [0319] 1.1.1 tool with upper and lower part, second guide means [0320] 1.2 process station, [0321] 1.2.1 first process station [0322] 1.2.2 n-th process station [0323] 1.3 path measuring/positioning system, second data memory and computer, [0324] 1.4 space, process area, workshop [0325] 1.4.1 space remote from the shape of a respective workpiece 2, 2.1 [0326] 2 workpiece, blank, component [0327] 2.1 workpiece to be machined, to be shaped, shaped, passenger car door [0328] 2.2 attachment point [0329] 2.3 interim storage facility [0330] 3 UAV [0331] 3.1 attachment means, vacuum suction cups, e-magnetic [0332] 3.1.1 axis, rotor axis [0333] 3.1.2 attachment element [0334] 3.1.3 rotor blade [0335] 3.2 optical means, camera. [0336] 3.3 first data memory with file and computer [0337] 3.3.1 device for determining position [0338] 3.3.2 safety control [0339] 3.3.3 measuring means, sensor [0340] 3.3.4 control element [0341] 3.3.5 line, cable, hose [0342] 3.4 sacrificial UAV [0343] 3.5 pool, battery, storage facility [0344] 3.6 lift means, propeller, jet [0345] 3.6.1 adjustable lift means, [0346] 3.6.2 lift means, can be operated coupled, providing effective lift [0347] 3.6.3 lift means, can be switched off, not providing effective lift [0348] 3.7 first guide means [0349] 3.8 joint kinematics [0350] 3.8.1 mechanical element [0351] 4 flight simulator [0352] control/regulating device [0353] F1 first flight pattern [0354] F2 second flight pattern