Processing apparatus

Abstract

Provided is a processing apparatus where the exchange of an operating program for an apparatus body is not required each time a jig unit is exchanged. The processing apparatus includes an apparatus body and a jig unit. A master control device is mounted on the jig unit. Operations of the jig unit and the apparatus body are controlled by an operating program in the master control device.

Claims

1. A processing apparatus comprising: an apparatus body; a jig unit exchangeable with respect to the apparatus body; a master control device mounted on the jig unit; and a slave control device mounted on the apparatus body, wherein the master control device and the slave control device include a communication device respectively, and an operation of the jig unit is controlled by an operating program in the master control device, and an operation of the apparatus body is controlled by the operating in the master control device with the slave control device through the communication device.

2. The processing apparatus according to claim 1, further comprising: another jig unit; and a second slave control device, including a communication device, mounted on the other jig unit, wherein the jig unit comprises an upper jig or a lower jig and the master control device is mounted on the jig unit as the upper jig or the lower jig and the other jig unit is the other of the upper jig and the lower jig on which the second slave control device is mounted, which is controlled by the operating program in the master control device through the second slave control device.

3. The processing apparatus according to claim 2, wherein the master control device, the slave control device, and the second slave control device are programmable logic controllers.

4. The processing apparatus according to claim 1, wherein the processing apparatus is a heat welding device, and the jig unit includes a heat welding unit where an operation of the heat welding unit is controlled by the master control device.

5. The processing apparatus according to claim 1, wherein in a state where the jig unit is removed from the processing apparatus, an operation of the apparatus body is controlled by the slave control device.

6. The processing apparatus according to claim 1, wherein: the master control device is mounted on one of an upper jig and a lower jig of the jig unit, and a second slave control device is mounted on another one of the upper jig and the lower jig of the jig unit; the second slave control device includes a communication device; and the jig unit on which the second slave control device is mounted is controlled by the operating program in the master control device with the second slave control device through the communication device.

7. The processing apparatus according to claim 6, wherein the master control device, the slave control device, and the second slave control device are programmable logic controllers.

8. The processing apparatus according to claim 7, wherein an operation of the apparatus body is controlled by the slave control device when the jig unit is removed from the processing apparatus.

9. The processing apparatus according to claim 6, wherein an operation of the apparatus body is controlled by the slave control device when the jig unit is removed from the processing apparatus.

10. The processing apparatus according to claim 1, wherein an operation of the apparatus body is controlled by the slave control device when the jig unit is removed from the processing apparatus.

11. A processing apparatus comprising: an apparatus body; a jig unit; a master control device is mounted on the jig unit, and operations of the jig unit and the apparatus body are controlled by an operating program in the master control device; a slave control device mounted on the apparatus body, wherein the master control device and the slave control device include a communication device respectively, and an operation control performed by the operating program in the master control device controls an operation of the apparatus body through the slave control device; another jig unit; and a second slave control device, including a communication device, mounted on the other jig unit, wherein the jig unit comprises an upper jig or a lower jig and the master control device is mounted on the jig unit as the upper jig or the lower jig and the other jig unit is the other of the upper jig and the lower jig on which the second slave control device is mounted, which is controlled by the operating program in the master control device through the second slave control device.

12. The processing apparatus according to claim 11, wherein the master control device, the slave control device, and the second slave control device are programmable logic controllers.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a diagram showing a schematic configuration where a welding device is mounted on a processing apparatus according to the invention;

(2) FIG. 2 is a diagram showing a schematic configuration of a conventional processing apparatus;

(3) FIG. 3 is a diagram showing a schematic configuration where a jig unit of the processing apparatus of the present invention is exchanged;

(4) FIG. 4 is a diagram showing a schematic configuration of a processing apparatus according to further aspects of the invention;

(5) FIG. 5 is a schematic explanatory view of a welding circuit in welding processing of an example 1;

(6) FIG. 6A to FIG. 6D are explanatory views of a welding step in the example 1;

(7) FIG. 7A is a schematic configuration diagram of an example 2, and

(8) FIG. 7B is an operation explanatory view of the example 2.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

(9) FIG. 1 is a diagram showing a schematic configuration where a welding device is mounted on a processing apparatus according to an embodiment of the present invention.

(10) In the embodiment of the present invention, a programmable logic controller (PLC) is used as a control device so that the control device is referred to as PLC hereinafter.

(11) As shown in FIG. 1, the processing apparatus 1 of this embodiment is formed of an apparatus body 2, and a jig unit 3 which is exchangeable with respect to the apparatus body 2. The jig unit 3 is formed of: an upper jig 3a on which the welding device 35 and a sensor 34 are mounted; and a lower jig 3b on which a master PLC 11, a manipulation panel 12, an electric cylinder 13, and a sensor 14 are mounted.

(12) The apparatus body 2 is formed of an electric cylinder 23 and a welding power source 25. A welding power is supplied to the welding device 35 of the upper jig 3a from the welding power source 25 through a welding power source connector 6.

(13) The sensor 34 of the upper jig 3a is a thermocouple of welding tips 36 of the welding device and a stroke sensor for the welding tips. Signals from the sensor are transmitted to the master PLC 11 via a communication connector 4 and a communication connector 5.

(14) An air supply coupler not shown in the drawing is disposed in combination with the communication connector 4 and the communication connector 5 respectively.

(15) Accordingly, air is supplied to the upper jig 3a and the lower jig 3b from the apparatus body 2 so as to cool an air driven clamping device not shown in the drawing and the welding tips 36.

(16) Plural kinds of jig units 3 are prepared corresponding to a product to be subjected to welding processing. Provided that devices to be mount on the jig unit 3 have the same functional configuration (a welding method and a required electrical energy), it is possible to freely change the number of welding points of the jig unit 3, the operation of the electric cylinder, a function of a sensor and the number of sensors to be used.

(17) The master PLC 11 performs, by an operating program stored in the master PLC 11, an operation control of the electric cylinder 13 of the jig unit 3 and, at the same time, an operation control of the electric cylinder 23 and the welding power source 25 of the apparatus body 2.

(18) In the processing apparatus 1 having the above-mentioned configuration, the operation control of the apparatus body 2 and the jig unit 3 is performed by the operating program in the master PLC 11 of the jig unit 3 so as to perform welding processing of a product.

(19) After an operator attaches the jig unit 3 to the apparatus body 2, all processing is performed by the control program in the master PLC 11. Accordingly, even when the jig unit 3 is attached to another apparatus body 2, it is unnecessary to perform an operation for exchanging a program and matching confirmation between a product and a program.

(20) Accordingly, even when a model of the apparatus is frequency changed according to production schedule requirements, by merely exchanging the jig unit 3, it is possible to start welding processing immediately without performing matching confirmation of the program.

(21) In the case of a conventional welding device 41 shown in FIG. 2, after a jig unit 43 is exchanged with respect to an apparatus body 42, it is necessary to change over an operating program in a master PLC 11 to an operating program which corresponds to the jig unit 43, and to confirm that the operating program definitely corresponds to the jig unit 43.

(22) The operating program depends on the control function of the master PLC 11. Accordingly, in renewing the jig unit 43 due to the changing over of the model of product to be processed, when the jig unit 43 is required to have a new function, there is a possibility that a function cannot be added depending on the control function of the master PLC 11. In such a case, it is necessary to exchange the master PLC 11.

(23) However, when the master PLC 11 is exchanged with a new master PLC, there is a concern of the new master PLC becoming incompatible with the jig unit 43 which is conventionally used. In such a case, there is a problem in that the advantage is lost which is gained by adopting a method where the jig unit is exchanged for the processing apparatus.

(24) FIG. 3 is a schematic explanatory view of a configuration where the jig unit 3 of the processing apparatus 1 of the present invention is exchanged with another jig unit 3. Simultaneously with the exchange of the jig unit 3 with the jig unit 3, the apparatus body 2 and the jig unit 3 are connected with the communication connectors 4, 5 and the welding power source connector 6. Accordingly, the jig unit 3 can be easily exchanged with the jig unit 3.

(25) An operating program dedicated to a jig is already introduced in each master PLC 11 so that there is no possibility of an operating program for another model being operated. Accordingly, when the jig unit 3 is exchanged, processing can be started immediately after the jig unit 3 is exchanged. Therefore, the time before processing starts after performing changeover can be shortened. Different from the conventional processing apparatus, it is unnecessary to read and install an operating program and to perform an operation check of the operating program. For this reason, an error in setting a program can be eliminated and, at the same time, a setup loss can be reduced.

(26) FIG. 4 shows the configuration where a slave PLC 21 is mounted on the apparatus body 2, and an operating program in the master PLC 11 controls an operation of the processing apparatus body through the slave PLC 21. The slave PLC 21 functions as a communication device between the master PLC 11 and the apparatus body 2.

(27) When the jig unit 3 is removed from the apparatus body 2, it may be also possible for the slave PLC 21 to manipulate the electric cylinder 23 in a single form.

EXAMPLE 1

(28) A welding example where the welding device is mounted on the processing apparatus of the present invention is described with reference to FIG. 4, FIG. 5, and FIGS. 6A to 6D.

(29) FIG. 4 shows a configuration where the slave PLC 21 is mounted on the apparatus body 2 of the processing apparatus 1 shown in FIG. 1 so as to function as a communication device with the master PLC 11. With the use of the above-mentioned communications protocol, a communication control of the master PLC 11 and the slave PLC 21 can be performed only by connecting a standardized communication connector. Accordingly, minimal connection failure and erroneous operation conditions can be maintained.

(30) The slave PLC 21 receives an operation command from the master PLC 11, and the slave PLC 21 operates with the same function as the master PLC 11 thus controlling the electric cylinder 23 and the welding power source 25 of the apparatus body 2.

(31) In controlling the operations of the electric cylinder 23 and the welding power source 25, the manipulation panel 22 of the apparatus body 2 possesses higher manipulability than the manipulation panel 12 of the lower jig 3b. Accordingly, the operation may be controlled by manipulating the master PLC 11 using the manipulation panel 22. With such a configuration, in the same manner as the welding device having the conventional configuration shown in FIG. 2, the operation can be controlled by performing a manipulation on the apparatus body 2 so that work efficiency is enhanced.

(32) FIG. 5 is a schematic explanatory view of a welding circuit. An operation signal from the operating program in the master PLC 11 of the lower jig 3b is transmitted to the slave PLC 21 of the apparatus body 2 through the lower jig communication connector 4, and the slave PLC 21 controls the welding power source 25.

(33) Corresponding to N number of welding points, N sets of members, each set being formed of a power regulator and a transformer, are mounted on the welding power source 25. In the explanatory view, an example is shown where welding is performed at three points by three welding tips mounted on the welding device 35. However, it is needless to say that a circuit configuration can be expanded or contracted by taking into account the number of welding points on a product to be processed and extensibility of the welding device.

(34) The welding tips 36 mounted on the welding device 35 are welding tips for impulse heating. A welding voltage supplied from the welding power source 25 is applied to the welding tips 36 through the welding power source connectors 6 thus heating the welding tips 36.

(35) Next, the manner of operation in a welding step is described from an attachment of the jig unit with reference to FIG. 6A to FIG. 6D.

(36) The welding step is performed using a known thermal caulking method so that the detailed description of the thermal caulking is omitted.

(37) FIG. 6A is an explanatory view of the apparatus body 2 and the jig unit 3. The welding device 35 is mounted on the upper jig 3a. A thermocouple (not shown in the drawing) is attached to each welding tip 36.

(38) The master PLC 11, the master manipulation panel 12 (not shown in the drawing), the electric cylinder 13 and a receiving base 17 are mounted on the lower jig 3b. The receiving jig 17 is moved by the electric cylinder 13 in the lateral direction.

(39) A lower portion of the apparatus body 2 is formed of the slave PLC 21 and the welding power source 25, and an upper portion of the apparatus body 2 is formed of an attachment plate 38 which is moved by the electric cylinder 23 in the vertical direction.

(40) As shown in FIG. 6B, in a state where the jig unit 3 is attached to the apparatus body 2, the upper jig 3a is clamped by the attachment plate 38. On the receiving base 17 of the lower jig 3b clamped by the lower portion of the apparatus body 2, a welding workpiece 15 and an object to be fixed 16 are placed in an overlapping manner with a welding boss 15a interposed therebetween.

(41) When a processing start button (not shown in the drawing) is pressed down, the electric cylinder 13 is operated by a command of the operating program in the master PLC 11 so as to move the welding workpiece 15 to a processing position in the processing apparatus 2.

(42) After the welding workpiece 15 is moved to the predetermined processing position, as shown in FIG. 6C, the command of the master PLC 11 reaches the electric cylinder 23 through the slave PLC 21 so that the upper jig 3a starts to move downward.

(43) After the upper jig 3a moves downward to a predetermined position shown in FIG. 6D, the welding tips 36 come into contact with the welding boss 15a thus starting thermal welding.

(44) The voltage applying command of the master PLC 11 reaches the welding power source 25 through the slave PLC 21. Then, a voltage of the welding power source 25 is applied to the welding tips 36 so that heat is generated at distal ends of the welding tips 36 whereby the welding boss 15a is welded (thermally caulked).

(45) After the welding boss 15a is welded up to a predetermined height, a voltage is stopped. Then, the welding tips 36 and the welding boss 15a are cooled by air by an air cooling circuit not shown in the drawing.

(46) After the welding tips 36 and the welding boss 15a are cooled down to a normal temperature, a supply of air is stopped, and the upper jig 3a moves upward to a predetermined position. Then, the welding workpiece 15 is moved to a start position. With such operations, the welding step is finished.

EXAMPLE 2

(47) With reference to FIG. 7A which is a schematic configuration diagram and FIG. 7B which is an operation explanatory view, as an example of further aspects according to the invention, a state is described where the processing apparatus is used as a camera inspection device for performing an appearance inspection of a product.

(48) To perform a control of the apparatus, as shown in FIG. 7A, a second slave PLC 31 is mounted on an upper jig in addition to a master PLC 11 mounted on a lower jig 3b and a slave PLC 21 mounted on an apparatus body 2.

(49) In the same manner as the example 1, the master PLC 11 controls all operations of the apparatus, and an electric cylinder and a manipulation panel of the apparatus body 2 are operated through the slave PLC 21.

(50) An operation command to a camera device 37 mounted on an upper jig 3a and measurement result information from the camera device 37 are subjected to communication control with the master PLC 11 connected to the camera device 37 through the second slave PLC 31.

(51) Next, an operation for performing an image inspection of a workpiece 15 using the camera device 37 is described with reference to FIG. 7B.

(52) When an operating program for performing the image inspection in the master PLC 11 is activated, the movement and the positioning of the workpiece 15 placed on the receiving base 17 are performed by the electric cylinder 13. Then, the camera device on the upper jig 3a is moved downward to a set position by the electric cylinder 23 so as to adjust a focus.

(53) Next, a command to perform the image inspection is transmitted to the camera device 37 from the master PLC 11 through the second slave PLC 31.

(54) The camera device 37 photographs the workpiece 15, and a good/bad determination of the workpiece is performed by an internal image processing. The inspection result of the workpiece 15 is transmitted to the master PLC 11 through the second slave PLC 31.

(55) After the appearance inspection is finished, the electric cylinder 13 and the electric cylinder 23 are commanded to return to initial positions by the master PLC 11, and the good/bad determination which is the inspection result is displayed on the manipulation panel 22. With such operations, the inspection is finished.

(56) In this example, the second slave PLC 31 is used as a communication control I/F between the master PLC 11 and the camera device 37. However, the application of the second slave PLC 31 is not limited to the communication control I/F. The second slave PLC 31 may perform a control of any of various kinds of devices such as a positioning device, a measuring device and a robot in a single form or in cooperation with the master PLC 11.

APPENDIX

Reference Signs List

(57) 1 processing apparatus 2 apparatus body 3 jig unit 3a upper jig 3b lower jig 4 lower jig communication connector 5 upper jig communication connector 6 welding power source connector 11 master PLC 12 master manipulation panel 13 electric cylinder 14 lower jig sensor 15 welding workpiece 15a welding boss 16 object to be fixed 17 receiving base 21 slave PLC 22 slave manipulation panel 23 electric cylinder 25 welding power source 31 second slave PLC 35 welding device 36 welding tip 37 camera device 38 attachment plate 41 processing apparatus having conventional configuration 43 jig unit having conventional configuration