Method for controlling a device system, which comprises a tool device and motorized advancing apparatus
10222784 ยท 2019-03-05
Assignee
Inventors
- Tobias DREXL (Weil, DE)
- Ralf Pfeiffer (Landsberg, DE)
- Roland SCHAER (Grabs, CH)
- Dieter Profunser (Zwischenwasser, AT)
Cpc classification
G05B2219/37583
PHYSICS
G05B2219/49097
PHYSICS
G05B2219/49088
PHYSICS
International classification
G05B19/416
PHYSICS
Abstract
A method for controlling a device system is disclosed, and the device system includes a tool device and a motorized advancing apparatus during the machining of a workpiece composed of a first material and a second material different from the first material. The method includes machining the workpiece by the device system initially in a first operating mode with first machining parameters that are stored for the first material. After the start of the machining of the workpiece in the first operating mode, the method includes measuring and storing a first machining progress of the tool device as a reference value. During the machining of the workpiece in the first operating mode, the method also includes regularly measuring and comparing with a first threshold value a current machining progress of the tool device.
Claims
1. A method for controlling a device system, wherein the device system comprises a tool device and a motorized advancing apparatus during the machining of a workpiece composed of a first material and a second material different from the first material, the method comprising the steps of: machining the workpiece by the device system initially in a first operating mode with first machining parameters that are stored for the first material; measuring a first machining progress of the tool device as a quotient of a path difference and a time difference and storing the first machining progress as a reference value after the start of the machining of the workpiece in the first operating mode; and measuring regularly and comparing with a first threshold value, which is a percentage of the reference value, a current machining progress of the tool device during machining of the workpiece in the first operating mode; wherein the workpiece is machined by the device system in the first operating mode when the current machining progress is within the first threshold value.
2. The method according to claim 1, further comprising switching the device system from the first operating mode to a second operating mode when the current machining progress is outside the first threshold value, and wherein the workpiece is machined by the device system in the second operating mode with second machining parameters that are stored for the second material.
3. The method according to claim 2, further comprising measuring regularly and comparing with a second threshold value the current machining progress of the tool device during the machining of the workpiece in the second operating mode.
4. The method according to claim 3, wherein the workpiece is machined by the device system in the second operating mode when the current machining progress is within the second threshold value.
5. The method according to claim 3, further comprising switching the device system from the second operating mode to the first operating mode when the current machining progress is outside the second threshold value, and wherein the workpiece is machined by the device system in the first operating mode with the first machining parameters that are stored for the first material.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1)
(2)
(3)
(4)
(5)
DETAILED DESCRIPTION OF THE DRAWINGS
(6)
(7) The tool device is formed as a core bore device 12 and includes a machining tool formed as a bore bit 14 that is arranged on a driveshaft 15 and is driven by a drive apparatus 16 in a rotational direction 17 around an axis of rotation 18. All drive components for the bore bit 14, with the exception of the driveshaft 15, are re-subsumed under the term drive apparatus. The drive apparatus 16 represented schematically in
(8) The device stand 11 consists of a ground plate 21, which is fastened to a substrate, and a guiding track 22, which is connected to the ground plate 21. The core bore device 12 is arranged over a guiding carriage 23 on the device stand 11 and is movable by way of the advancing apparatus 13 along the guiding track 22 in an advancing direction 24 that runs parallel to the axis of rotation 18. The advancing apparatus 13 includes a motorized advancing apparatus 25 and a manual advancing apparatus 26 formed as a hand wheel. The core bore device 12 can optionally be run with the motorized advancing apparatus 25 or manual advancing apparatus 26 along the guiding track 22 of the device stand 11. The device system 10 is operated via a first operating unit 27 attached to the motorized advancing apparatus 25 and a second operating unit 28 attached to the core bore device 12. The motorized advancing apparatus 25 is connected to the core bore device 12 via a communication cable 29.
(9) The first operating unit 27 includes, for example, multiple operating buttons, a display, and an emergency shutoff switch, and the second operating unit 28 can be formed as a rotary selector. Alternatively or additionally, a remote control unit can be provided that is connected via communication connections to a control unit of the core bore device 12 and/or a control unit of the motorized advancing apparatus 25. The communication connections can be formed as wireless communication connections in the form of infrared, Bluetooth, WLAN, or Wi-Fi connections or as cabled communication connections. In addition to the listed wireless connection technologies, all previously known and future wireless connection technologies are suitable for data transmission.
(10)
(11) The drive apparatus 16 includes a bore motor 31, a gear mechanism apparatus 32, and electronics apparatus 33 having a power electronics unit 34 and a control unit 35 for controlling and regulating the core bore device 12. The driveshaft 15 is driven by the bore motor 31 and the gear mechanism apparatus 32 around the axis of rotation 18, whereby the gear mechanism apparatus 32 is arranged between the bore motor 31 and the driveshaft 15. The bore motor 31, the gear mechanism apparatus 32, and the electronics apparatus 33 are arranged in the device housing 19 of the core bore device 12.
(12) The motorized advancing apparatus 25 includes an advancing motor 36, a gear mechanism apparatus 37, a driveshaft 38, and an electronics apparatus 39 having a power electronics unit 41 and a control unit 42 for controlling and regulating the motorized advancing apparatus 25. The advancing motor 36, the gear mechanism apparatus 37, and the electronics apparatus 39 are arranged in a housing 43. The first operating unit 27 is integrated into the top of the housing 43.
(13) Control and regulation of the core bore process take place by way of the control units 35, 42. The goal of the control and regulating process for core boring is to optimally use the available power of the device system 10 and at the same time not to reduce the service life of the bore bit 14 and the drive apparatus 16. In addition, inexperienced users are to be enabled to achieve optimal machining results (quality, time, etc.). The machining and regulating parameters by which optimal machining results are achieved primarily depend on the diameter of the bore bit 14 and the material to be machined. Concrete and steel in the form of concrete reinforcing bars are especially relevant as materials for core boring. In addition, boring requires adjusted machining and regulating parameters.
(14) In the control unit 42 of the motorized advancing apparatus 25, lookup tables are stored that include optimized machining and regulating parameters for core boring. For every bore bit diameter, multiple parameter sets are stored. The parameter sets include the know-how for the machining process and take into account the various basic conditions for tapping, boring of concrete (concrete boring), and for boring of concrete reinforcing bars (iron bores). If additional materials are to be machined, appropriate parameter sets with optimized machining and regulating parameters for the additional materials can be stored in the lookup tables.
(15)
(16) The method for controlling the device system 10 when creating the through bore 52 in the reinforced concrete ceiling 53 can be subdivided into six phases: (1) detection of the top 55, (2) tapping, (3) concrete boring of the first concrete area 56, (4) iron boring of the iron area 57, (5) concrete boring of the second concrete area 58, and (6) breaking through the bottom 59. With respect to the blind bore 51, which in of
(17) The first phase is referred to as surface detection. Here, a manual example and an automatic example of the surface detection can be distinguished. In the manual example, the core bore device 12 is driven by the operator with the assistance of the hand wheel 26 into the position in which the bore bit 14 touches the surface 55 of the reinforced concrete ceiling 53, the operator confirms via the operating unit 27 at the motorized advancing apparatus 25 that the bore bit 14 touches the surface 55 of the reinforced concrete ceiling 53, and the control unit 42 stores this position of the bore bit 14 as zero position z=0.
(18) In the automatic example, the reaching of the surface 55 can be detected, for example, with the assistance of the advancing speed of the bore bit 14. At the advancing motor 36, a constant rotational speed is set that is converted to a constant advancing speed over the guiding carriage 23 of the bore bit 14, which is referred to as the target speed v.sub.target. When the bore bit 14 touches the top 54, the bore bit 14 is slowed down and there is a rapid decline in, the advancing speed. The current advancing speed v.sub.actual of the bore bit 14 can be recorded with the assistance of a sensor apparatus. The difference between the current advancing speed v.sub.actual of the bore bit 14 and the target speed v.sub.target is calculated and compared with a preset value. If the difference exceeds the preset value, the position of the bore bit 14 is stored in the control unit 42 as zero position z=0.
(19) As soon as the zero position of the bore bit 14 is stored, the first phase is ended and the second phase begins. The second phase is referred to as tapping. To avoid polishing the bore bit 14, the motor output and advancing speed are initially reduced for core boring. When the cutting segments of the bore bit 14 have pierced the surface 55 and are located in the first concrete area 56, the bore bit 14 is guided and polishing of the bore bit 14 is avoided. To securely prevent polishing, the second phase of the tapping is executed via a tapping depth d.sub.A.
(20) The machining parameters for the device mode tapping are reduced compared to the device mode concrete boring. The tapping depth d.sub.A and the machining parameters suitable for tapping are stored in the control unit 42. In practice, a tapping depth d.sub.A of 2 mm has proved to be suitable. As a matter of principle, the tapping depth d.sub.A should be selected so that the tapping phase is ended at the depth of the reinforcing bars 54. For manual surface detection, the second phase must be started by the operator manually, whereas the second phase for automatic surface detection can also be started automatically by the device system 10.
(21) As soon as the bore bit 14 has reached the tapping depth d.sub.A, the second phase of tapping is ended and the third phase begins. The third phase is referred to as concrete boring of the first concrete area 56. The device system 10 is switched from the device mode tapping to the device mode concrete boring. The machining parameters for the core bore device 12 and the motorized advancing apparatus 25 are adjusted to the boring of concrete. The reinforcing bars 54 are arranged at least 40 mm below the top 55 of the reinforced concrete ceiling 53 and the tapping depth d.sub.A is less than the distance between the top 55 and the reinforcing bars 54, so that, as a matter of principle, the concrete boring phase follows tapping.
(22) Once the bore bit 14 touches a reinforcing bar 54, the third phase is ended and the fourth phase begins. The fourth phase is referred to as iron boring of the iron area 57. The device system 10 is switched from the device mode concrete boring to the device mode iron boring. The machining parameters for the core bore device 12 and the motorized advancing apparatus 25 are adjusted to the boring of concrete reinforcing bars.
(23) Once the bore bit 14 touches the second concrete area 58, the fourth phase is ended and the fifth phase begins. The fifth phase is referred to as concrete boring of the second concrete area 58. The device system 10 is switched from the device mode iron boring to the device mode concrete boring. The machining parameters for the core bore device 12 and the motorized advancing apparatus 25 correspond to the machining parameters of the third phase.
(24) Once the bore bit 14 has bored through the second concrete area 58, the fifth phase is ended and the sixth and final phase of the control method according to the invention begins. The sixth phase is referred to as breaking through the bottom 59. The through bore 52 is made in the reinforced concrete ceiling 53 when the bore bit 14 has reached the bottom of the reinforced concrete ceiling 53.
(25) In order to be able to automatically control the device system 10 with the core bore device 12 and the motorized advancing apparatus 25, the device system 10 must recognize whether the bore bit 10 bores concrete or machines a reinforcing bar 54. The decision of whether the bore bit 14 will bore in a concrete area 56, 58 or will impinge on a reinforcing bar 54 in the iron area 57 is made with the assistance of a bore progress v with respect to the method according to the invention for controlling the device system 10. As bore progress v, a quotient consisting of a path difference z and a time difference t is defined that therefore represents a speed. The bore progress v can be calculated in that at the start and at the end of a fixed time interval t the positions z.sub.1, z.sub.2 of the bore bit 14 are measured. Alternatively, the necessary time t=t.sub.2t.sub.1 can be measured for preset positions z.sub.1, z.sub.2 with z=z.sub.2z.sub.1 of the bore bit 14.
(26) After switching the device system 10 from the second to the third phase, a first bore progress is calculated which is defined as the reference value v.sub.ref for the concrete boring as part of the control method. All other bore progresses that are calculated during the method are compared with the reference value v.sub.ref. Because the tapping depth d.sub.A has been selected so that the phase of tapping is ended in any case at the depth of the reinforcing rods 54, this ensures that concrete will be machined after tapping.
(27) As long as the bore bit 14 machines the first concrete area 56, the deviations of the bore progress v.sub.current from the reference value v.sub.ref are less than approximately +/20%*v.sub.ref. One of the reasons for the deviations from the reference value v.sub.ref is irregularities in the concrete. As soon as the bore bit 14 is no longer boring in the first concrete area 56, but rather impinging on the reinforcing bar 54 in the iron area 57, there is a clear drop-off in the current bore progress v.sub.current. This dramatic change in the bore progress is used to switch to the fourth phase, iron boring of the iron area 57. To that end, the current bore progress v.sub.current is specified and compared with a preset first threshold value G.sub.1. The first threshold value G.sub.1 corresponds to a percentage of the reference value v.sub.ref and is 40% of the reference value v.sub.ref, for instance. The bore bit 14 machines concrete as long as the current bore progress v.sub.current is not less than the first threshold value G.sub.1 (v.sub.currentG.sub.1). If the current bore progress v.sub.current is less than the first threshold value G.sub.1 (v.sub.current<G.sub.1), concrete is not machined, but rather the second material different from the concrete, in
(28) During the iron boring phase, the machining parameters of the device system 10 are adapted to the boring of the reinforcing rod 54. As soon as the boring bit 14 no longer machines the reinforcing rod 54, but rather machines the concrete in the second concrete area 58, there is a clear increase in the current bore progress v.sub.current. This dramatic change in the bore progress is used to switch to the fifth phase, the concrete boring of the second concrete area 58. To that end, the current bore progress v.sub.current is specified and compared with a preset second threshold value G.sub.2. The second threshold value G.sub.2 corresponds to a percentage of the reference value v.sub.ref and is 60% of the reference value v.sub.ref, for example. The bore bit 14 machines the iron area 57 as long as the current bore progress v.sub.current is less than the second threshold value G.sub.2 (v.sub.current<G.sub.2). If the current bore progress v.sub.current exceeds the second threshold value G.sub.2, (v.sub.currentG.sub.2), the bore bit 14 has left the iron area 57 and machines the second concrete area 58. The first and second threshold values G.sub.1, G.sub.2 are determined by the operator before starting the core bore process and are stored in the lookup tables of the control unit 42.
(29) The end of the core bore with respect to the through bore 52 can likewise be monitored with the help of the current bore progress v.sub.current and of the reference value v.sub.ref. If the bore bit 14 has completely bored through the second concrete area 58, then the bottom 59 of the reinforced concrete ceiling 53 is penetrated. The bore bit 14 does not experience any resistance and there is a dramatic increase in the current bore progress v.sub.current. This dramatic change of the bore progress can be used to switch off the device system 10. To that end, the current bore progress v.sub.current is compared with a preset third threshold value G.sub.3. The third threshold value G.sub.3 corresponds to a percentage of the reference value v.sub.ref and is 250% of the reference value v.sub.ref, for example. An increase of the bore progress of more than 150% of the reference value v.sub.ref can only occur if the reinforced concrete ceiling 53 has been penetrated at the bottom 59.
(30)
(31) In a step S01 the operator sets the diameter of the bore bit 14 via the rotary selector 28 and the geometry of the bore hole via the first operating unit 27 (blind bore 51 with bore hole depth d.sub.T).
(32) Alternatively, the diameter of the bore bit 14 likewise can be entered via the first operating unit 27. In a step S02, the operator drives the bore bit 14 into the zero position and stores the zero position at the first operating unit 27. Then, the operator starts the method in a step S03 via the first operating unit 27.
(33) The control unit 42 sets the machining parameters in a step S04 at the advancing motor 36 and via the control unit 35 at the bore motor 31, which are stored in the lookup tables for tapping (second phase). For each bore bit diameter, multiple parameter sets are stored in the control unit 42 with suitable machining parameters for tapping, boring of concrete (concrete boring), and the boring of concrete reinforcing bars (iron boring). Before starting the method, the bore motor 31 and the advancing motor 36 are switched off. The core bore device 12 and the motorized advancing apparatus 25 are switched on in a step S05 and are operated with the machining parameters set in step S04 for tapping.
(34) The control unit 42 in a step S06 measures the current bore depth d.sub.actual by way of a suitable sensor unit and in a step S07 checks whether the preset tapping depth d.sub.A is reached. The current bore depth d.sub.actual is measured at a preset time interval. If the current bore depth is below the preset tapping depth (d.sub.actual<d.sub.A in S07), the method is continued with step S05. If the preset tapping depth d.sub.A is reached (d.sub.actuald.sub.A in S07), the tapping phase is ended. Steps S04 to S07 are referred to as tapping phase T.sub.1.
(35) When the tapping phase T.sub.1 is ended, the control unit 42 in a step S08 at the advancing motor 36 and via the control unit 35 at the bore motor 31 sets machining parameters that are stored in the lookup tables of the control unit 42 for the bore bit diameter for concrete boring. The core bore device 12 and the motorized advancing apparatus 25 are operated in a step S09 with the set machining parameters for the concrete boring.
(36) In a step S10, the position z of the bore bit 14 in a preset time interval is measured by a path sensor or a comparable sensor and transmitted to the control unit 42. The control unit 42 calculates in a step S11 the first bore progress from the measurement values and stores the first bore progress as a reference value v.sub.ref. The core bore device 12 and the motorized advancing apparatus 25 are operated in a step S12 with the machining parameters for concrete boring. The current position of the bore bit 14 is measured in a step S13 and transmitted to the control unit 42 of the motorized advancing apparatus 25.
(37) The control unit 42 calculates in a step S14 from the position of the bore bit 14 the current bore depth d.sub.actual and compares the current bore depth d.sub.actual in a step S15 with the set bore hole depth d.sub.T of the blind bore 51. If the preset bore hole depth d.sub.T is reached (d.sub.actuald.sub.T in S15), the core bore is ended. Then, the bore bit 14 must be removed from the reinforced concrete ceiling 53 whereby this step can be manually carried out by the operator or automatically by the device system 10. In the automatic example, the control unit 42 switches the core bore device 12 and the motorized advancing apparatus 25 in a step S16 to a parking mode. Machining parameters appropriate to the parking mode for the core bore device 12 and the motorized advancing apparatus 25 are stored in the control unit 42. The core bore device 12 and the motor advancing apparatus 25 are operated in a step S17 with the set machining parameters until the core bore device 12 has reached a preset parking position. The parking position can be defined, for example, as a zero position with an additional offset of 10 cm above the surface 55. The method according to the invention is ended after step S17.
(38) If the current bore depth d.sub.actual is less than the preset bore hole depth d.sub.T (d.sub.actual<d.sub.T in S15), the core bore is continued. The control unit 42 calculates in a step S18 from the measurement values transmitted in step S13 the current bore progress v.sub.current and compares the current bore progress v.sub.current in a step S19 with the preset first threshold value G.sub.1. If the current bore progress v.sub.current is not less than the first threshold value G.sub.1 (v.sub.currentG.sub.1 in S19), the core bore device 12 and the motorized advancing apparatus 25 are further operated in the concrete boring phase and the method according to the invention is continued with step S12. The current position of the bore bit 14 is measured with a frequency.
(39) If the current bore progress v.sub.current exceeds the first threshold value G.sub.1 (v.sub.current<G.sub.1 in S19), the control unit 42 in a step S20 switches the advancing motor 36 and via the control unit 35 the bore motor 31 from the concrete boring phase to the iron boring phase. To that end, the control unit 42 at the advancing motor 36 and at the bore motor 31 sets the machining parameters, which are stored in the lookup tables of the control unit 42 for the iron boring phase. The core bore device 12 and the motorized advancing apparatus 25 are operated in a step S21 with the set machining parameters for the iron boring.
(40) The current position z of the bore bit 14 is measured in a step S22 at the distance of time interval t and transmitted to the control unit 42 of the motorized advancing apparatus 25. The control unit 42 calculates in a step S23 from the current position of the bore bit 14 the current bore depth d.sub.actual and compares the current bore depth d.sub.actual in a step S24 with the bore hole depth d.sub.T. If the preset bore hole depth d.sub.T is reached (d.sub.actuald.sub.T in S24), the core bore is ended and the method is continued with step S16. If the current bore depth d.sub.actual is less than the preset bore hole depth d.sub.T (d.sub.actual<d.sub.T in S24), the core bore is continued and the control unit 42 calculates in a step S25 from the measurement values the current bore progress v.sub.current.
(41) In a step S26, the current bore progress v.sub.current is compared with the preset, second threshold value G.sub.2. If the current bore progress v.sub.current is less than the second threshold value G.sub.2 (v.sub.current<G.sub.2 in S26), the core bore device 12 and the advancing module 26 are further operated in the iron boring phase and the method is continued with step S21. If the current bore progress v.sub.current is not less than the second threshold value G.sub.2 (v.sub.currentG.sub.2 in S26), the control unit 42 in a step S27 switches from the iron boring phase to the concrete boring phase. The core bore device 12 and the motorized advancing apparatus 25 are operated with the machining parameters, which are stored in the lookup tables of the control unit 42 for the concrete boring phase. The method is continued with step S12.
(42)
(43) With respect to the control method according to the invention based on
(44) If the current bore progress v.sub.current exceeds the third threshold value G.sub.3 (v.sub.currentG.sub.3 in S45), the bore bit 14 has reached the bottom 59 of the reinforced concrete ceiling 53. The control unit 42 switches the core bore device 12 and the motorized advancing apparatus 25 in a step S46 to the parking mode. Appropriate machining parameters for the parking mode of the device system 10 are stored in the control unit 42. The device system 10 is operated in a step S47 with the set machining parameters for the parking mode until the core bore device 12 has reached the preset parked position. The method according to the invention is ended after step S47.
(45) If the current bore progress v.sub.current is less than the third threshold value G.sub.3 (v.sub.current<G.sub.3 in S45), then the current bore progress v.sub.current is compared by the control unit 42 in a step S48 with the first threshold value G.sub.1. If the current bore progress v.sub.current is not less than the first threshold value G.sub.1 (v.sub.currentG.sub.1 in S48), the device system 10 is further operated in the concrete boring phase and the method according to the invention is continued with step S42. If the current bore progress v.sub.current is less than the first threshold value G.sub.1 (v.sub.current<G.sub.1 in S48), the device system 10 in a step S49 is switched to the iron boring phase, and the method according to the invention is continued with steps S50 and S51 which match the steps S21 and S22.
(46) In a step S52, the control unit 42 calculates from the measurement values transmitted in step S51 the current bore progress v.sub.current and compares the current bore progress v.sub.current in a step S53 with the preset third threshold value G.sub.3. If the current bore progress v.sub.current exceeds the third threshold value G.sub.3 (v.sub.currentG.sub.3 in S53), the bore bit 14 has reached the bottom 59 of the reinforced concrete ceiling 53. The method according to the invention is continued with steps S46 to S47 and is ended after step S47.
(47) If the current bore progress v.sub.current exceeds the third threshold value G.sub.3 (v.sub.current<G.sub.3 in S53), then the current bore progress v.sub.current is compared by the control unit 42 in a step S54 with the second threshold value G.sub.2. If the current bore progress v.sub.current is less than the second threshold value G.sub.2 (v.sub.current<G.sub.2 in S54), the device system 10 is further operated in the iron boring phase and the method is continued with step S50. If the current bore progress v.sub.current exceeds the second threshold value G.sub.2 (v.sub.currentin S54), the control unit 42 switches the device system 10 in a step S55 from the iron boring phase to the concrete boring phase and the method according to the invention is subsequently continued with step S42.
(48) In addition to the machining parameters for the three phases tapping, concrete boring, and iron boring, regulation parameters adjusted for each bore bit diameter for regulating the motor parameters in the concrete boring and iron boring phases can be stored in the lookup tables of the control unit 42. During machining, the current motor parameters (rotational speed, torque) of the bore motor 31 are measured and transmitted to the control unit 42 of the motorized advancing apparatus 25. The control unit 42 calculates from the transmitted measurement values a deviation between the current motor parameters (actual values) and the motor parameters stored in the control unit 42 (target values). The calculated deviation is compared with a preset maximum deviation .sub.max. If the deviation is less than the maximum deviation (<.sub.max), the motor parameters at the advancing motor 36 and at the bore motor 31 remain unchanged and the advancing motor 36 is operated with the current motor parameters. If the deviation exceeds the maximum deviation (.sub.max), the control unit 42 calculates adjusted motor parameters for the advancing motor 36 and the bore motor 31 and sets these adjusted motor parameters at the motors 36, 31.