PRODUCTION SYSTEM, PRODUCTION MODULE, METHOD FOR OPERATING AND SETTING UP A PRODUCTION LINE, AND METHOD FOR PRODUCING A WORKPIECE

Abstract

The underlying invention relates in particular to a production module for a production line which is modularly populatable with production modules. In embodiments, provision is made whereby the production module comprises at least one manipulator unit with which a workpiece or a workpiece component is, during the production process, transferable between a deposit position and a production position in the production space of a production module which, for the execution of a production step, is positioned directly downstream in a production direction (R) along the production line.

Claims

1-26. (canceled)

27. A production module, in particular a press module, designed for executing at least one production step in a method for producing a workpiece, and configured for integration into a modular production system with multiple production modules which are arranged successively in relation to one another along a production line, and which have production spaces for forming a production channel running along the production line, comprising: at least one manipulator unit; wherein: the manipulator unit comprises, upstream or downstream of the production module in the direction of the production line, a deposit system with at least one deposit unit for depositing a workpiece or a workpiece component; the deposit system is configured such that a workpiece or a workpiece component is, during the production process, transferable between a deposit position of the deposit unit and a production position in the production space of a production module; and for the execution of a production step, the production module is positioned directly downstream in a production direction (R) along the production line.

28. The production module as claimed in claim 27, wherein the manipulator unit comprises: at least one displacement carriage, wherein the at least one displacement carriage is: mounted so as to be displaceable parallel to the wide side (B) of the production module and transversely, in particular laterally, with respect to the production direction (R) along the production line, positioned upstream or downstream of the working space in the production direction (R) along the production line; and wherein the at least one displacement carriage enables a workpiece or a workpiece component to be movable, in particular outward away from the production line or inward toward the production line, between a deposit position assigned to the production space and at least one further deposit position which is laterally spaced apart from the deposit position, in particular from the production line.

29. The production module as claimed in claim 28, wherein: the manipulator unit comprises at least two, in particular exactly two, displacement carriages; the displacement carriages are, preferably by means of a displacement unit, in particular a linear displacement unit, each movable, in particular laterally perpendicularly with respect to the production line, in particular in synchronized fashion, between: a first position, which is assigned to the production space or to the production line, and at least one second position, which is laterally averted from the production space or the production line, in particular at least one second position which is situated laterally at least partially outside the production channel of the production line.

30. The production module as claimed in claim 27, comprising: a further manipulator unit configured for transferring the or a workpiece or the or a workpiece component between: the deposit position of a deposit unit positioned upstream and/or downstream of the production module, and the production position in the production space of the respective production module.

31. The production module as claimed in claim 27, wherein the at least one deposit system is attached to a wide side of the production module, in particular to a wide side of a frame of the production module.

32. The production module as claimed in claim 27, wherein the deposit system is configured to: execute separate and/or additional process functions, including in particular rotating, marking and performing process and/or quality control on workpieces or workpiece components; and/or transfer in or transfer out workpieces or workpiece components.

33. The production module as claimed in claim 27, further comprising: a mechanical connecting unit for the exchangeable mechanical coupling of the production module to a platform assigned to the production line; wherein the platform comprises multiple production module installation locations (P), which are modularly populatable with production modules, for the exchangeable positioning and setting-up of production modules; wherein the production modules are in particular arranged successively one behind the other along the production line.

34. The production module as claimed in claim 27, further comprising: a control interface configured for exchangeably detachable coupling in terms of control technology to a corresponding complementary control interface of the production system; wherein the control interface and the complementary control interface are configured for: the exchange of, in particular control and/or process signals relating to, the operation of the manipulator unit, and/or the execution of a production operation by means of a production unit of the production module.

35. The production module as claimed in claim 27, further comprising: a control unit for the control of the production module for the execution of production operations; wherein: the control unit is operable in an operating mode as a slave control unit for implementing control commands of a master controller; and the master controller is superordinate in terms of control technology, of the production system.

36. A production system comprising: a production module; and at least one, preferably at least two or more, modularly exchangeably populatable production module installation locations (P) which is/are each modularly exchangeably populatable with the production module; wherein the production module is designed for executing at least one production step in a method for producing a workpiece, and configured for integration into a modular production system with multiple production modules which are arranged successively in relation to one another along a production line, and which have production spaces for forming a production channel running along the production line, comprising: at least one manipulator unit; wherein: the manipulator unit comprises, upstream or downstream of the production module in the direction of the production line, a deposit system with at least one deposit unit for depositing a workpiece or a workpiece component; the deposit system is configured such that a workpiece or a workpiece component is, during the production process, transferable between a deposit position of the deposit unit and a production position in the production space of a production module; and for the execution of a production step, the production module is positioned directly downstream in a production direction (R) along the production line.

37. The production system as claimed in claim 36, wherein at least one production module installation location (P) is modularly exchangeably populatable or populated with a production module for subtractive, formative and/or additive production of a workpiece.

38. The production system as claimed in claim 36, further comprising: a first control unit configured as a master controller and configured in terms of control technology for communication with a second control unit; wherein: the second control unit is operable as a slave controller, of at least one of the production modules; and the second control unit is optionally selectively operable independently of the master controller.

39. A method for manufacturing a workpiece by means of a production system having at least one production module, comprising at least one of the following steps: (i) transferring a workpiece or a workpiece component by means of a manipulator unit between a deposit position, assigned to a production line, of a deposit unit and a production position, positioned directly downstream of the deposit position in a production direction (R) along the production line, in a production space of a production module, wherein the manipulator unit is assigned to the production module and is optionally controlled by a controller of the production module; or (ii) transferring the workpiece or the workpiece component between a deposit position assigned to the production line and a further deposit position, in particular outside the production line, by transfer of the deposit unit with the workpiece situated thereon or the workpiece component situated thereon between the deposit position and the further deposit position, wherein a manipulating and/or production intermediate step is optionally performed in the deposit position or in the further deposit position.

40. A computer program product comprising commands which are executable by a processor or computing unit configured for controlling a production plant, wherein the execution of the commands by the processor or computing unit in the production plant implements the method as claimed in claim 39.

41. A controller comprising means, in particular a processor or computing unit, configured for controlling a production plant by executing the method as claimed in claim 39.

42. A production module, wherein the production module is a press module for the processing, in particular for the forming, of workpieces preferably composed at least partially of metal and is configured for modular integration into a production line which is in the form of a press line, and which has at least one production module installation location (P) in the form of a modularly populatable press module installation location (P), and which has multiple processing stations; comprising: an in particular peripherally closed press frame; at least one press plunger which is movably mounted on the press frame and which is designed for the processing of workpieces; a drive which, at one side, is coupled in terms of drive to the press plunger and, at the other side, is fastened to the press frame; a working space, which is assigned to the press plunger and which is formed within the press frame and which is configured for the processing of workpieces, as production space; and optionally a manipulator device for workpieces, which manipulator device comprises a first manipulator unit which is in particular fastened to the press frame and which has at least one first manipulator for workpieces.

43. The production module as claimed in claim 42, wherein the first manipulator unit or the at least one first manipulator is: arranged at least partially in at least one recess adjoining the working space; extends laterally outward transversely with respect to the movement axis (A) of the press plunger; and optionally fastened to the press frame.

44. The production module as claimed in claim 42, wherein: the production module is configured for modular integration into a press line which has at least one modularly populatable production module installation location (P) and which has multiple processing stations; and the production module further comprises a second manipulator unit with at least one second manipulator; the at least one second manipulator is arranged, in particular fastened to the press frame, at a wide side (B), situated transversely with respect to the feed direction (R), of the press frame, and the at least one second manipulator is positioned upstream or downstream of the working space.

45. The production module as claimed in claim 44, wherein: the at least one second manipulator comprises at least one displacement carriage; and the at least one displacement carriage is: mounted so as to be displaceable parallel to the wide side (B) and transversely with respect to the feed direction (R), and positioned upstream or downstream of the working space in the processing direction (R), and configured to move a workpiece laterally outward away from the working space or inward toward the working space.

46. The production module as claimed in claim 45, wherein the at least one second manipulator comprises: at least two, in particular exactly two, displacement carriages; and the at least two displacement carriages are, by means of a displacement unit, each positionable, in particular in synchronized fashion, at a first position, which is situated at the production space, and at a second position, which is laterally averted from the working space, in particular a second position which is situated laterally at least partially outside the press frame.

47. The production module as claimed in claim 42, further comprising: a mechanical connecting unit for the exchangeable mechanical coupling of the press module to a platform assigned to a press line, wherein the platform comprises multiple press module installation locations (P) that are modularly populatable with press modules, for the exchangeable positioning and setting-up of press modules; and/or an electrical, in particular electronic, interface configured for exchangeably detachable coupling to a corresponding counterpart interface of the press line.

48. A production system, in particular press line, comprising: at least two modularly exchangeable press modules, which are arranged along a processing line at corresponding press module installation locations (P) and which serve for the processing of workpieces, in particular for the formative processing of workpieces preferably composed at least partially of meta; wherein: each of the press modules comprises a press frame and a driveable press plunger movably mounted therein; each press plunger is assigned a working space which is designed for the processing of workpieces; the press modules are arranged successively in relation to one another such that the working spaces form a processing channel along the processing line; the press modules are arranged at processing positions, which are fixedly predefined for a respective operating mode, along the processing line; and at least one of the press modules, preferably each of the press modules, is integrated, as a unit which is exchangeable as a whole, into the processing line at the respective processing position at the corresponding press module installation location (P).

49. The production system as claimed in claim 48, further comprising: at least two mounting pedestals designed for exchangeably receiving a press module; wherein: a respective press module comprises at least one mounting interface designed for mechanical coupling to the mounting pedestal; optionally: the mounting pedestal and the mounting interface comprise mutually corresponding coupling elements by means of which a respective press module may be exchangeably integrated into the processing line; and/or the mounting pedestal is designed as a tray-like insert or comprises such an insert, wherein the insert is designed such that one of the press modules may be removed from the press line in a direction transverse, in particular perpendicular, to the processing line; optionally, the insert comprises a guide system, in particular linear guide system, preferably a rail system, by means of which in each case one of the press modules is couplable and displaceable transversely, in particular perpendicularly, with respect to the processing line, such that a respective press module is: (i) removable and insertable transversely, in particular perpendicularly, in relation to the processing line; and/or (ii) is positionable such that its working space is situated in alignment with the processing channel, or is situated outside the processing line.

50. The production system as claimed in claim 48, further comprising: a control interface which is coupled via a wired or wireless data communication means, in particular a control bus, to a press line controller; and wherein the control interface serves for: in particular wired or wireless, coupling in terms of signal technology to a complementary interface of a press module which is modularly exchangeably integrated at a press module installation location (P); and transmission of control commands and/or operating parameters of the press module.

51. The production system as claimed in claim 48, wherein at least one of the modularly exchangeable press modules comprises: a press module controller by means of which the operation of the components of the press module is at least partially, preferably completely, controllable; and optionally further comprises a monitoring unit for receiving, for acquiring and for data processing of operating parameters of the individual, in particular modularly exchangeable press modules.

52. A method for setting up a production line, in particular a press line, which is modularly populatable with production modules, in particular press modules, of a production system, wherein at least one processing position which is modularly populatable with an exchangeable production module is set up for a production module, the method comprising: mechanically installing an exchangeable production module at the at least one modularly populatable production position by means of mechanical coupling elements for exchangeable replacement of a production module; and connecting the installed production module in terms of control technology to a master controller of the production line; and integrating the installed production module into an operating sequence along the production line.

53. The method as claimed in claim 52, the method further comprising: transmitting, preferably after connection in terms of control technology of at least one exchangeable production module, control parameters for the control of the at least one exchangeable production module to the at least one exchangeably integrated production module, in particular from a master controller, designed for controlling all production modules, of the production line, and/or control parameters for the control of the at least one exchangeable production module and/or for the control of the entirety of the production modules are transmitted to the master controller of the production line; and/or transmitting, after installation of the exchangeable production module, control parameters for the operation of the production module and/or control parameters for the operation of the production line from a memory integrated into a communication network at the location of the production line, or from a memory or computer at a location remote from the location of the production line via a further communication network, to the communication network of the production line for the purposes of the control of the production line.

54. A method for generating operating parameters for a production system having at least one modularly exchangeably populatable production module installation location (P), comprising: generating, on a test production module, or a test production system, an operating and/or control parameter dataset corresponding to a predefined operating mode, and optionally a predefined number and type of operating situations, and tools, in a test run; and performing at least one of the following: transmitting, optionally, for the configuration of the production module or production line of substantially identical construction to the test production module or to the test production line respectively and designed for production purposes, the generated operating and/or control parameter dataset directly to the production module or the production line respectively; or storing the generated operating and/or control parameter dataset in a buffer memory provided for transmission to the production module or to the production line respectively.

55. The method as claimed in claim 54, wherein the operating and/or control parameter dataset is, for the purposes of operational setup, transmitted from the buffer memory to the production module or to the production line, the method further comprising: reading in of an operating and/or control parameter dataset from a portable memory medium, a local data memory or computer connected to a data communication network, or a data memory at a remote location and connected to a data communication network; inserting or exchanging, optionally, at least one press module of the press line at a modularly populatable press module installation location (P), and operating; and/or reading in control parameters for the inserted or exchanged press module at the press line by the memory medium or the local or remote data memory; and/or inserting in addition to the operating parameters, at least one, preferably all, of the tools associated with the operating parameters into respective production modules.

Description

[0193] Exemplary embodiments of the present invention will be described in more detail below on the basis of the following figures, in particular on the basis of a forming or press module and a forming or press line. In the Figures:

[0194] FIG. 1 shows a perspective view of a press module without inserted press tools;

[0195] FIG. 2 shows the press module as per FIG. 1 with inserted press tools;

[0196] FIG. 3 shows the press module of FIG. 1 in a view from above;

[0197] FIG. 4 shows the press module of FIG. 1 in a side view;

[0198] FIG. 5 shows the press module of FIG. 2 in a side view;

[0199] FIG. 6 shows the press module of FIG. 1 in a front view;

[0200] FIG. 7 shows the press module of FIG. 2 in a front view;

[0201] FIG. 8 shows a manipulator unit of the press module;

[0202] FIG. 9 shows a press line with multiple press modules; and

[0203] FIG. 10 shows a production system with production modules, which production system is designed in a configuration with an angled production line and interposed buffer unit.

[0204] FIG. 1 shows, as an example for a production module, a forming or press module 1 for the processing, in particular for the forming, of workpieces, preferably at least partially composed of metal, in particular sheet-metal. The workpiece may be produced from one or more different materials, and may for example comprise components composed of different metals and/or plastic.

[0205] The press module 1 is configured and designed for modular integration into a press line 2, as shown in FIG. 9, with multiple successive working positions and press module installation locations which are assigned to the working positions and which are modularly exchangeably populatable with press modules.

[0206] The press module 1 of FIG. 1 comprises a peripherally closed press frame 3, and a press plunger 5 which is mounted, and supported so as to be slidable, on an inner flank 4 of the press frame 3 and which serves for the processing of workpieces.

[0207] The press plunger 5 is coupled in terms of drive technology to a drive, in the present case a hydraulic cylinder 6 as linear motor, and may be moved up and down by corresponding operation of the hydraulic cylinder 6 by means of a control unit (which is not explicitly shown).

[0208] The drive, that is to say the hydraulic cylinder 6, is fastened to an upper side of the press frame.

[0209] The press plunger 5 is supported and mounted, so as to be slidable, on the press frame by means of sliding elements 7, which are attached to beveled edges of the inner flanks 4, and corresponding guide elements 8 which are mechanically connected to the press plunger 5 and which are beveled correspondingly to the edges. By means of the mounting of the press plunger by means of four beveled sliding edges which are situated opposite one another in each case in pairs, substantially tilt-free support may be realized.

[0210] The press module 1 has, adjoining the movement space of the press plunger 1, a working space 9 in which a workpiece for processing may be positioned during operation.

[0211] Two recesses 10 are formed, so as to adjoin the working space 9 and so as to communicate with the working space 9, on the press frame 3. The recesses 10 extend laterally outward to both sides of the working space 9.

[0212] A first manipulator device 11 as shown in FIG. 8 is arranged or mounted in each of the recesses 10 for the purposes of transporting workpieces into and out of the working space 9.

[0213] Furthermore, a press table 12 is present or formed, opposite the press plunger 5, on the press frame.

[0214] In the embodiment according to the figures, the spaces for receiving the press plunger 5, the press table 12, the working space 9, and, furthermore, the recesses 10, respectively formed within the press frame 3, are formed as apertures extending through the press frame 3, that is to say corresponding locations on the press frame 3 are formed as passages extending through the press frame 3, whereby, for example, the accessibility to the components of the press module 1 may be improved and the weight of a press module 1 may be optimized, which is advantageous in particular with regard to the modular exchangeability of the press modules 1.

[0215] At the narrow sides, the press frame 3 may have in each case two flanges 13 which project at the press frame edges, such that the narrow sides have an outwardly open U-shaped cross section. By means of a corresponding form of the narrow sides, it is possible in particular to achieve a compromise between reduced weight, sufficient torsional stiffness and stability of the press frame. The narrow sides of U-shaped cross section resulting from the flanges 13 may be clearly seen in the plan view shown in FIG. 3.

[0216] The press frame 3 of the present embodiment is of symmetrical form in relation to a central plane running through the working axis A of the press plunger 5, which may be advantageous with regard to the assembling of multiple press modules 1 in a press line 2 and with regard to the modularity and modular exchangeability, proposed herein, of press modules 1.

[0217] The press module 1 furthermore comprises a second manipulator device 14 which is attached to, in particular flange-mounted on, the press frame 3 at a wide side B, lying transversely with respect to the feed direction R, of the press frame 3, and which in the present example is positioned upstream of the working space 9 in the feed direction R. As seen in a front view, the second manipulator device 14 is attached at least partially below the working space. The fastening of the second manipulator device 14 at least partially above the working space, in particular to the press frame, for example with corresponding grippers for gripping a workpiece or other components, is likewise possible.

[0218] The second manipulator device 14 comprises two manipulators which, in the present case, are formed as displacement carriages 15. The displacement carriages 15 are, in the present exemplary embodiment, coupled to a linear guide 16 running parallel to the wide side B, in particular a linear guide rail with corresponding drives, in particular linear drives. The linear guide 16 and the displacement carriages 15 are designed such that the displacement carriages are displaceable in a synchronous manner parallel to the wide side 15, such that one of the displacement carriages 15 may be positioned at the working space 9 while the second displacement carriage is positioned at a laterally outer end of the linear guide 16, for example at least partially outside the press frame 3.

[0219] By means of the second manipulator device 14, it is possible, for example during ongoing operation of the press module 1, for a workpiece to be moved outwards, for example transferred outwards, by virtue of the deposit carriage 15, or displacement carriage, situated at the working space 9 being moved outwards with a workpiece situated thereon. At the same time, the deposit carriage 15 situated at the outside may be moved inwards to the working space 9, and may be used there for the deposit or receiving of a workpiece.

[0220] Furthermore, by means of the second manipulator device 14, an additional element, for example a construction element such as a threaded element and the like, may be fed to the working space 9, for example in order to be connected to or integrated into a workpiece in a processing step.

[0221] The second manipulator device 14 may also be used, as already described above, for integrating additional process steps, such as for example rotation of the workpiece, marking of the workpiece, welding, cutting etc.

[0222] FIG. 2 shows the press module 1 with inserted tools, wherein an upper tool 17 is coupled to the press plunger 5 and a lower tool 18 is coupled to the press table 12.

[0223] For the change of the tools 17, 18, the press module 1 furthermore comprises spherical-roller rails 19 fastened to one side, in particular narrow side, of the press frame 3, wherein the spherical-roller rails 19 are provided and designed to move the upper and lower tools 17, 18 into the working space 9 and out of the latter during a tool change.

[0224] FIG. 4 and FIG. 5 show side views of the press module 1, wherein it can be seen from these side views that the press frame 3 has, at each lateral side (one of the lateral sides is visible in plan view in FIG. 4 and FIG. 5), at the level of the working space 9, a lateral aperture 20 which communicates with the working space 9. The lateral apertures 20 are formed such that, together with the working space 9, they form a channel which extends in a lateral direction, in particular perpendicular to the workpiece flow direction R, and which is designed such that a tool situated in the working space 9 may be removed and inserted in a lateral direction. In the present example, both apertures 20 have the same shape and the same diameter and are of symmetrical form in relation to a central plane running through the working axis A.

[0225] FIG. 6 and FIG. 7 show the press module 1 in a front view, wherein it can be clearly seen from these figures that the first manipulator devices 11 may be arranged in the recesses 10. By means of the recesses 10, it may firstly be achieved that the freedom of movement and the available movement volume for the first manipulator devices 11 is increased, resulting in advantages for the transport of workpieces into the working space 9 and out of the working space 9. It is furthermore possible to implement a relatively compact construction.

[0226] In particular, there are advantages for the placement and positioning of a workpiece on the lower tool 18, and for the removal of a workpiece from the lower tool 18.

[0227] An exemplary embodiment of a first manipulator device 11 is shown in more detail in FIG. 8. In the specific example of FIG. 8, the first manipulator device 11 comprises a manipulator 21 with one or more gripping members 22 designed for gripping a workpiece 27. The manipulator is coupled to an actuator unit 23, which in the present example permits a movement of the gripping member 22 or of the manipulator 21 in three movement directions.

[0228] Specifically, the first manipulator device 11 comprises three actuators 25 which are mounted in a linearly displaceable manner on respective linear guides 24 and which may be moved along the linear guides 24 in order to thus move the manipulator 21 or the gripping member 22.

[0229] The linear guides 24 are arranged in three mutually perpendicular directions, wherein, in the installed state, a first linear guide is oriented parallel to the working axis A, a second linear guide is oriented parallel to the workpiece flow direction R, and wherein a third linear guide is formed perpendicular thereto, and permits a movement component laterally toward and away from the working space 9.

[0230] One of the actuators 25 comprises a mounting plate 26 for cantilevered fastening to the press frame 3.

[0231] As can be seen from FIGS. 1 to 7, a first manipulator device 11 is mounted on each lateral side of the working space 9, wherein the first manipulator devices 11 are for example operable synchronously such that a workpiece 27, in the working cycle of the press module, moves in the workpiece flow direction R, may be placed for processing in the working space 9, in particular on a corresponding lower tool 18, may be removed from the respective tool 18 after the processing, and may for example be placed on a deposit carriage 15.

[0232] FIG. 9 shows a production line, by way of example on the basis of a press line 2, with multiple modularly exchangeably populatable press module installation locations P. Press module installation locations P of the press line are, in the example of FIG. 9, populated with press modules 1, wherein the press modules 1 are arranged successively one behind the other in a workpiece flow direction. The press modules 1 of the press line 2 are preferably of identical form.

[0233] In the exemplary embodiment of FIG. 9, the press line 2 comprises a feeder unit 28, by means of which a sheet-metal strip as starting material may be fed to the press modules 1 from a corresponding roll, that is to say a corresponding sheet-metal coil 29.

[0234] In the present example, a first processing unit 30 comprising two press modules 1 installed in a modularly removable manner at press module installation locations P, is positioned downstream of the feeder unit 28 in the workpiece flow direction R. The first processing unit 30 may for example be configured for working processes such as cutting and punching.

[0235] In the example of FIG. 9, a buffer unit 31 is positioned downstream of the processing unit 30 in the workpiece flow direction R, which buffer unit is designed to receive and temporarily store, that is to say buffer, workpieces 27. The buffer unit 31 may for example be designed in terms of receiving capacity such that the time required for a change of a sheet-metal coil 29 may be bridged, such that the second processing unit 32 positioned downstream of the buffer unit 31 may continue to be operated even during a change of a sheet-metal coil 29.

[0236] The second processing unit 32 comprises, by way of example, a total of nine press modules 1 which are configured to further process the stages generated by the first processing unit, for example by means of a series of forming operations, to realize the end product. The further press modules 1 of the second processing unit 32 are installed in a modularly exchangeable manner at corresponding press module installation locations P of the press line 2.

[0237] A further operative unit for receiving and for transporting away the finished workpiece is arranged downstream of the second processing unit 32 in the workpiece transport direction R.

[0238] The press modules 1 may be constructed in accordance with a press module described in conjunction with FIGS. 1 to 8, wherein the press modules 1 of the first processing unit 30 (cutting, punching etc.) may be operated with relatively short press strokes, and wherein the press modules 1 of the second processing unit (forming, bending etc.) may be operated with longer press strokes.

[0239] As already mentioned, all press modules 1 may be of identical construction (aside from the tools used). This is advantageous in particular for provision of replacement parts and exchange of modularly integrated press modules 1. In particular, it is not strictly necessary for each of the exchangeably integrated press modules 1 to hold available a respective substitute press module.

[0240] The press modules 1 of the press line 2 are arranged successively in relation to one another, such that the working spaces 9 of the processing units form, along the respective processing line, a processing channel for transporting workpieces.

[0241] The press line 2 comprises a rail system 33 with multiple rails 34 assigned to the press module installation locations, which rails are shown in FIG. 9 in the region of the processing units 30, 32. The press modules 1 are coupled to the rail system 33 by means of corresponding mechanical interfaces, which may be formed for example on the lower side of the press frame 3, for example corresponding rollers. The coupling of the press modules 1 to the rail system 33 is such that each press module 1 may be removed from the press network from the respective press module installation location by displacement along the respective rail 34. At the same time, it is possible for a further press module 1, which is for example held available as a substitute and which is populated or populatable or to be populated with corresponding tools, and which likewise is or may be coupled to the rail system 33, to be incorporated or integrated into the press network by means of the rail system 33 at a corresponding press module installation location P.

[0242] With the rail system 33, each of the press modules 1 is, in the present example, integrated, at the respective processing position or at the respective press module installation location P, as a functional unit which is exchangeable as a whole, including the manipulator devices, into the processing line. The number of exchangeably integrated or integrable press modules 1 may vary, for example depending on the type of press line 2 and type of workpiece to be manufactured.

[0243] An advantage of the modularly exchangeable press modules 1 and of the modularly exchangeable integration of the press modules 1 by means of a guide system, such as for example the rail system 33 or some other system by means of which the press modules may be easily and quickly exchanged, consists in that servicing and repair of a press module 1 may, after removal from the press assembly, be performed outside the press line 2. By insertion of a substitute press module, the press line 2 may continue to be operated substantially without major interruptions, such that the downtimes of the press line 2 required for example for servicing and repair may be considerably reduced. It is also possible for a defective press module to be replaced in a simple manner and without long interruptions in the production process.

[0244] It is furthermore possible for the press line 2 to be comparatively easily converted, for example for manufacturing a workpiece of a different type, or in conjunction with the incorporation of another modular processing unit or of another modular press module, that is to say of a modularly exchangeable press module, in place of a modularly exchangeably integrated press module 1 or a corresponding processing unit. In particular, processing steps may be exchanged, interchanged, supplemented and/or varied, for example by exchange or variation of the sequence or arrangement of the press modules 1 of the processing stations along the processing line.

[0245] The press line 2 may be operated in accordance with the manner described further above, wherein reference is made in particular to the above discussion in connection with the exchange or change of press modules 1. Furthermore, reference is made to the above discussion made in connection with the try-out presses and the setup of control, press and process parameters, which are correspondingly applicable.

[0246] The rail system 33 of the exemplary embodiment of FIG. 9 comprises a multiplicity of rails 34 which are arranged along the processing line and which are arranged transversely, in particular perpendicularly, with respect to the processing line, that is to say workpiece flow direction R. It is thus possible for individual press modules 1, which are modularly integrated at respective press module installation locations, to be moved out of the press network transversely with respect to the processing line. At a press module 1 which has been moved out, various components, such as for example press plunger 5, press table 12, the manipulator devices 11, 14 etc., are better accessible. Brief servicing work may be performed relatively easily in the case of a press module 1 which has been moved out. A removed press module 1, that is to say a press module 1 which has been moved out by means of the rail system 33, may also be replaced with another, in particular identically set-up, further press module 1. With regard to advantages, reference is made to the discussion above.

[0247] The rail system 33 may extend substantially in any desired manner proceeding from the press line 2. In particular, the press line 2 may be connected to or populated with a magazine with reserve or replacement press modules or other processing units by way of the rail system 33, such that, for example, individual press modules 1 may be exchanged for other press modules and/or processing units at any time. It is also possible for other processing units, for example for welding, cutting or marking operations etc., to be coupled or couplable to the rail system 33, such that these further processing units may also be integrated in modularly exchangeable fashion into the press line 2.

[0248] Furthermore, the guide system, in particular the rail system 33, may be configured such that multiple processing centers or press lines may be connected to one another, such that individual press modules 1 between the processing centers may be exchanged, and the processing centers may be configured in a correspondingly flexible manner.

[0249] Preferably, the individual press modules 1 have dedicated control units which permit autonomous operation of an individual press module 1, and which are preferably configured so as to be controllable synchronously by means of a superordinate master controller in a press network.

[0250] In the press network, for example in the case of integration into a press line 2 of FIG. 9, the control units of the press modules 1 may be connected to a superordinate master control unit which is configured for controlling all of the processing units and for synchronizing the operation of all processing units of the press line 2.

[0251] By virtue of the fact that the press modules may be configured with different operating modes, in particular corresponding to stand-alone operation and operation in the press network, it is possible, for example in the case of a correspondingly configured guide system, in particular the rail system 33, to selectively set up processing centers with individual press modules 1 in stand-alone operation or processing centers with multiple press modules 1 combined with one another in network operation.

[0252] In embodiments, further processing units, such as for example material feed, transporting-away of workpieces, buffer units etc., may likewise be designed to be movable by means of a or the guide system, in particular the rail system 33, and integrable in modularly exchangeable fashion into the press line 2, such that flexible setup of a processing center is possible.

[0253] The rail system 33 shown in conjunction with FIG. 9 allows the press modules 1 to be slid out laterally. In embodiments, the rail system 33, or some other guide system, may be configured such that a displacement of one or more press modules 1 or respective processing units is also possible parallel to the processing line. This yields further advantages and facilitations for the setup of a press line or of a processing center.

[0254] FIG. 10 shows a production system with production modules 1′ which is designed in a configuration with an angled production line 2′ and an interposed buffer unit 31.

[0255] The production modules 1′ are installed or designed in modularly exchangeable fashion analogously to the press modules 1 of the press line 2 of FIG. 9. In particular, the production modules 1′ may, on the basis of rails 34, be removed from the production network and inserted, or replaced, transversely, in particular locally in each case perpendicularly, with respect to the production line.

[0256] In the example of FIG. 10, the production line 2′ is designed in an angled configuration, wherein a first partial production line 30′ with multiple production modules 1′ connected in series is arranged substantially perpendicular to a second partial production line 32′, in turn comprising multiple production modules 1′ connected in series.

[0257] The production modules 1′, in particular some of the production modules 1′, may in particular be designed such that a deposit unit as described further above, in particular functioning as an intermediate store, is arranged or present at least between two, or at least between multiple, preferably in each case between two, production modules of the production line 2′, for example of the first or second partial production line 30′, 32′, which are arranged in immediate succession in the production direction R. Thus, between the successive production modules 1′, workpiece transport between the production spaces 9 thereof is possible by means of the deposit unit. By means of the deposit unit, for example by means of corresponding manipulators, or tools, it is possible for manipulating operations such as rotating or turning, or intermediate production steps, to be performed. Furthermore, it is possible for workpieces to be transferred out and/or for workpiece components to be transferred in.

[0258] At the end of the production line 2′ in terms of the production process, there may be provided an end store 35, at or by means of which the workpieces that have passed through the production line 2′ may be stored or discharged. Each of the partial production lines 30′ and 32′ may itself in turn be regarded as an independent production line 2′ in the context of the invention, in particular because each of the partial production lines 30′ and 32′ comprises at least one production module 1′ with a deposit unit which is designed as an intermediate store and which permits intermediate depositing or intermediate positioning of a workpiece between production spaces which are arranged in immediate succession in the production direction R.

[0259] It is evident that the production modules proposed herein for modular exchangeable integration into a production line with one or more modularly populatable production module installation locations offer in particular the advantages in terms of production and plant technology mentioned in the introduction.

[0260] The features and embodiments described herein in conjunction with production modules, production lines and production module installation locations apply in particular to, and are in particular applicable in the case of, press modules, press lines and press module installation locations.

LIST OF REFERENCE DESIGNATIONS

[0261] 1 Press module [0262] 1′ Production line [0263] 2 Press line [0264] 2′ Production line [0265] 3 Press frame [0266] 4 Inner flank [0267] 5 Press plunger [0268] 6 Hydraulic cylinder [0269] 7 Slide element [0270] 8 Guide element [0271] 9 Working chamber [0272] 10 Recess [0273] 11 First manipulator device [0274] 12 Press table [0275] 13 Flange [0276] 14 Second manipulator device [0277] 15 Deposit carriage [0278] 16 Linear guide [0279] 17 Upper tool [0280] 18 Lower tool [0281] 19 Spherical-roller rails [0282] 20 Lateral aperture [0283] 21 Manipulator [0284] 22 Gripping member [0285] 23 Actuator unit [0286] 24 Linear guide [0287] 25 Actuator [0288] 26 Mounting plate [0289] 27 Workpiece [0290] 28 Feeder unit [0291] 29 Sheet-metal coil [0292] 30 First processing unit [0293] 30′ First partial production line [0294] 31 Buffer unit [0295] 32 Second processing unit [0296] 32′ Second partial production line [0297] 33 Rail system [0298] 34 Rail [0299] 35 End store [0300] A Working axis [0301] B Wide side [0302] P Press module installation location [0303] R Workpiece flow direction