DEVICE AND METHOD FOR THE AUTOMATED PROCESSING OF WORKPIECES

Abstract

An apparatus for automated machining, such as grinding, cutting and/or deburring, of workpieces, in particular of cast components, e.g., of wind turbines. For this purpose, the apparatus comprises a motor spindle for machining the workpiece, the motor spindle having a tool interface for receiving a tool for the machining operation. Moreover, the motor spindle is designed, in particular, to change a tool automatically. In addition, the apparatus comprises a robot for holding and guiding the motor spindle, and a control unit for controlling the motor spindle and the robot. The disclosure additionally relates to a method for automated machining of workpieces.

Claims

1. An apparatus for automated machining of workpieces, that are cast components of wind turbines, the apparatus comprising: a motor spindle for machining the workpiece, the motor spindle having a tool interface for receiving a tool for performing a machining operation, and the tool interface being configured to pick up, set down, and change the tool automatically, a robot for holding and guiding the motor spindle, and a control unit for controlling the motor spindle and the robot.

2. The apparatus according to claim 1, further comprising: a travelling carriage, having a travel drive for moving the motor spindle and the robot between a plurality of positions within one or more halls, and tracks or rails for carrying and guiding the travelling carriage.

3. The apparatus according to claim 1, further comprising an operator cabin for accommodating at least one operator, the operator cabin having at least one access door, the operator cabin being disposed so as to be rotatable on the travelling carriage, independently of a movement of the robot.

4. The apparatus according to claim 3, comprising at least one of the following: an emergency off switch disposed in the operator cabin for interrupting a machining step, a presence switch disposed in the operator cabin for confirming presence inside the operator cabin, at least one door contact for monitoring at least one operator cabin door, and at least one gate contact for monitoring at least one hall gate.

5. The apparatus according to claim 1, comprising a tool cabinet for storing one or more tools, the tool cabinet having an automatic door or a roller shutter that is configured to be opened and closed by the control unit.

6. The apparatus according to claim 1, comprising at least one laser for measuring distances between at least one predefined point of the robot and at least one point of the workpiece.

7. The apparatus according to claim 1, comprising at least one of the following: a first camera for transmitting images of the workpiece to the control unit, a second camera configured to be disposed in a plurality of positions on the robot or the motor spindle for transmitting images of the workpiece to the control unit, and a monitor for displaying the images recorded by the camera or cameras.

8. The apparatus according to claim 1, comprising a cooling system for cooling the motor spindle.

9. The apparatus according to claim 1, comprising an input device for transmitting commands, that are input manually, to the control unit.

10. The apparatus according to claim 1, wherein the control unit has a delimiting circuit for delimiting movement of the robot.

11. The apparatus according to claim 1, comprising at least one of access request switches, a pause function, and a pause function switch, for requesting access to a region in which the workpiece is being machined.

12. The apparatus according to claim 1, comprising a manipulator for receiving a workpiece.

13. A method comprising: automated machining of workpieces of a workpiece that is a cast component of wind turbines, the automated machining comprising the steps: a travel step, in which a travelling carriage of the apparatus according to claim 2 is driven to the workpiece, a gauging step, in which the workpiece is gauged by at least one of a camera and a laser, a machining step, in which the workpiece is machined by the motor spindle in accordance with a default settings of the control unit.

14. The method according to claim 13, comprising a preparation step, in which, after the travel step and before the gauging step, the apparatus is prepared for the machining operation by closing of at least one hall gate and the connecting of the apparatus to one or more supply lines and data lines.

15. The method according to claim 13 comprising at least one of a workpiece selection step program selection step, in which commands are sent to the control unit by an input/output device in response to one of a plurality of predefined workpieces is selected and one or more of predefined machining programs are selected.

16. The method according to claim 13, the gauging step having a correction step, in which the control unit enables the manual positioning of the robot in order to control the robot manually with the aid of a remote control during the gauging step and to intervene in the automatic gauging.

17. The method according to claim 13, the machining step having a pre-cutting step, in which parts of the workpiece are pre-cut, a parting step, in which parts of the workpiece are parted off, and a grinding step, in which parts of the workpiece are ground.

18. The method according to claim 13, the method having a monitoring step for monitoring the presence of an operator in the operator cabin and for monitoring access to the hall in which the workpiece is being reworked.

19. The method according to claim 13 comprising a rotation step in which the operator cabin is rotated by actuation of at least one of manual switches and pushbuttons.

20. The method according to claim 13, the machining step having at least one tool change step in which a tool is automatically inserted in a tool interface of the motor spindle or delivered from the tool interface, the tool interface brought, by the robot, into the region of an automatically opening tool cabinet.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0045] The invention is described in greater detail in the following on the basis of exemplary embodiments and with reference to the accompanying figures. There are shown in:

[0046] FIG. 1 a view of an exemplary embodiment of the apparatus;

[0047] FIG. 2 an enlarged representation of an exemplary embodiment of the robot comprising a motor spindle;

[0048] FIG. 3 an enlarged view of an exemplary embodiment of the motor spindle;

[0049] FIG. 4 a view of an exemplary embodiment of the operator cabin;

[0050] FIG. 5 a view of an exemplary embodiment of the tool cabinet, and

[0051] FIG. 6 a view of an exemplary embodiment of the apparatus in the case of a machining step of an exemplary embodiment of the method.

DETAILED DESCRIPTION

[0052] FIG. 1 shows an exemplary embodiment of the apparatus 10 for executing an exemplary embodiment of the method according to the invention. The apparatus 10 comprises a travelling carriage 12, on which further components of the apparatus 10 are disposed. In particular, a robot 14 comprising a motor spindle 16, and an operator cabin or driver's cabin 18 and a tool cabinet 20 are disposed on the travelling carriage 12. The travelling carriage 12 has a travel drive, not represented, and can be moved on tracks or rails 22. During travel, i.e., in travel steps, along the rails 22, a trailing cable 24 is reeled up or reeled off by means of a cable reel 26, according to the direction of movement on the tracks 22. The apparatus 10 is located in a hall 28, which can be entered or exited through a gate 30, only a portion of which is represented. By means of the travelling carriage 12, the apparatus 10 can be moved into the hall 28 and moved out of the hall 28, through the gate 30. By means of the tracks 22 and the travelling carriage 12, it is possible to move the robot 14, with the motor spindle 16, into the region of a workpiece, e.g., a cast component of a wind turbine. The robot 14 then holds and guides the motor spindle 16 for the purpose of machining the workpiece. During the machining operation, the motor spindle 16 is cooled by means of a water cooling system 31.

[0053] FIG. 2 shows an enlarged representation of the robot 14 comprising the motor spindle 16. The motor spindle 16 has a tool interface 32 for receiving tools that are used to machine a workpiece. The robot 14 has a plurality of joints, in particular revolute joints 34, in order to move or guide the motor spindle on any paths before and during the machining operation, or in machining steps. Before the machining operation, such movements by means of the joints 34 are necessary in order to gauge the workpiece in one or more gauging steps. Remarks relating to gauging follow in the explanations relating to FIG. 3. Also represented is a control unit 36 that, by operating the joints 34, moves the robot 14 in such a manner that the motor spindle 16 can be moved on predefined paths. For this purpose, the control unit 36 is pre-programmed for one or more different workpieces, one or more different regions of the respective workpiece or workpieces, and one or more different types of machining of the respective region or regions.

[0054] FIG. 3 shows an enlargement of the motor spindle 16 from FIG. 2. A first camera 38 is fixedly mounted on the motor spindle 16. A second camera 40 can be disposed at various positions of the motor spindle 16, and for this purpose can be mounted and demounted particularly easily. Here, the second camera 40 is represented only in a first position. In addition, a laser 42 is attached to the motor spindle 16.

[0055] Before the machining of a workpiece by means of a tool received by the motor spindle 16, the workpiece is measured out, or gauged, to enable the apparatus 10 to perform precise machining. For the purpose of this gauging, the cameras 38, 40 and the laser 42 are attached to the motor spindle 16. The measuring-out of the workpiece is effected automatically, in that the cameras 38, 40 and the laser 42 transmit their acquired information to the control unit 36, and this acquired information in the control unit 36 determines, from the information or data, the relative position of the motor spindle 16 in relation to the workpiece. Moreover, the cameras 38, 40 serve for hazardless, close-proximity observation during the machining of the workpiece. According to an exemplary embodiment, the second camera 40 has a laser, which likewise serves for gauging. The second camera 40 has to be demounted following the gauging operation, or gauging step, and mounted before the gauging operation, since otherwise it would be in the working during the machining of the workpiece. According to an embodiment that is not represented here, the mounting and demounting are effected by moving the second camera 40 into differing positions in an automated manner, such that gauging is effected entirely automatically.

[0056] FIG. 4 shows the driver's cabin, or operator cabin 18. The driver's cabin has a seat 44 for the driver, and has a cabin door 46. During the machining operation, the cabin 18 protects a driver or operator against dust and noise. The driver's cabin 18 additionally has protective grilles 48, in order also to protect the operator against parts that become detached and fly around during the machining operation. All operating elements for the automatic operation and manual operation of the machine, including monitors for control and monitoring, are located in the driver's cabin 18. In addition, the seat 44 provides an ergonomically favorable position and protection against flying parts. According to an exemplary embodiment, the operator cabin 18 additionally has protective glass panes, instead of conventional panes, in order to offer addition protection against flying parts. A step 50 allows ease of access to the driver's cabin 18. By means of a pedal control, not represented, the driver's cabin 18 can be rotated by up to 180, thereby enabling the operator always to face towards the tool in the motor spindle 16, without having to turn in an ergonomically unfavorable manner on the seat 44. The cabin 18 can be rotated into the travel direction for the purpose of moving the travelling carriage 12.

[0057] FIG. 5 shows the tool cabinet 20, which comprises a housing 52. Here, the tool cabinet 20 is shown open, but it can be closed at the top by means of a roller shutter 54. The tools 56 are thus stored in the tool cabinet 20 to protect them against dirt, in particular on the part that is received by the tool interface. The tools 56 are, for example, cutting and grinding tools. The tools 56 are automatically removed from the tool holders 58, and set down therein, by the robot 14. The roller shutter 54 is automatically opened and closed for this purpose. Mounted in the lower part of the tool cabinet 20 is a frequency converter, which is ventilated by means of a ventilation system in order to prevent damage resulting from overheating. The frequency converter serves to operate the motor spindle 16.

[0058] FIG. 6 shows the apparatus 10 during the machining of a workpiece 60. For this purpose, the workpiece 60 is fixedly mounted on a turnover positioner 62, also called a manipulator. According to an exemplary embodiment, the manipulator 62 is a constituent part of the apparatus 10. The robot 14 in this case guides the motor spindle 16, with the received tool 56, along the region of the workpiece 60 to be machined. This process is effected automatically, according to the default settings of the control unit 36.

[0059] It is thus possible for the workpiece 60 to be machined in a substantially automatic manner, without the need for grinding or cutting to be performed manually by a person. Machining of the workpiece is thus effected with maintenance of stringent safety measures and with consideration of the health of personnel.