U.S. patent application number 16/603139 was filed with the patent office on 2021-10-14 for deformation processing support system and deformation processing support method.
This patent application is currently assigned to KAWASAKI JUKOGYO KABUSHIKI KAISHA. The applicant listed for this patent is KAWASAKI JUKOGYO KABUSHIKI KAISHA. Invention is credited to Atsuki NAKAGAWA, Naohiro NAKAMURA, Shinichi NAKANO.
Application Number | 20210319570 16/603139 |
Document ID | / |
Family ID | 1000005721732 |
Filed Date | 2021-10-14 |
United States Patent
Application |
20210319570 |
Kind Code |
A1 |
NAKAGAWA; Atsuki ; et
al. |
October 14, 2021 |
DEFORMATION PROCESSING SUPPORT SYSTEM AND DEFORMATION PROCESSING
SUPPORT METHOD
Abstract
A deformation processing support system acquires target shape
data of a work having a reference line; acquires intermediate shape
data from the work in an intermediate shape having a reference line
marked thereon; and overlaps the two data on each other by aligning
the reference lines relative to each other, to calculate a
necessary deformation amount of the work based on a difference
between the two data overlapped on each other. To align the
reference lines with each other, first and second alignment axes
with the same length calculated for the respective reference lines
are superimposed on each other. Subsequently, the intermediate
shape data is relatively rotated with respect to the target shape
data around the first alignment axis.
Inventors: |
NAKAGAWA; Atsuki;
(Kakogawa-shi, JP) ; NAKANO; Shinichi; (Suita-shi,
JP) ; NAKAMURA; Naohiro; (Kobe-shi, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
KAWASAKI JUKOGYO KABUSHIKI KAISHA |
Kobe-shi, Hyogo |
|
JP |
|
|
Assignee: |
KAWASAKI JUKOGYO KABUSHIKI
KAISHA
Kobe-shi, Hyogo
JP
|
Family ID: |
1000005721732 |
Appl. No.: |
16/603139 |
Filed: |
March 26, 2018 |
PCT Filed: |
March 26, 2018 |
PCT NO: |
PCT/JP2018/012009 |
371 Date: |
October 4, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G06T 2207/30164
20130101; G05B 2219/49184 20130101; G06T 7/593 20170101; G06T 7/521
20170101; G06T 7/564 20170101; G05B 19/4099 20130101; B21D 22/18
20130101; B21D 11/203 20130101; G06T 2207/10028 20130101 |
International
Class: |
G06T 7/521 20060101
G06T007/521; G06T 7/593 20060101 G06T007/593; G06T 7/564 20060101
G06T007/564; B21D 22/18 20060101 B21D022/18; B21D 11/20 20060101
B21D011/20; G05B 19/4099 20060101 G05B019/4099 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 6, 2017 |
JP |
2017-076003 |
Claims
1. A deformation processing support system calculating a necessary
deformation amount necessary for deformation from an intermediate
shape of a work to a target shape thereof based on a difference
between the intermediate shape and the target shape in deformation
processing for the work, the deformation processing support system
comprising: a target shape data acquiring part that acquires target
shape data of the work having a reference line disposed on a
surface thereof; an intermediate shape data acquiring part that
acquires intermediate shape data from the work having the
intermediate shape and having a reference line marked on a surface
thereof, during the deformation processing; and a necessary
deformation amount calculating part that overlaps the target shape
data and the intermediate shape data on each other by aligning the
reference lines relative to each other to calculate the necessary
deformation amount for each of plural positions on the work based
on a difference between the target shape data and the intermediate
shape data overlapped on each other, wherein as the overlapping of
the target shape data and the intermediate shape data on each
other, the necessary deformation amount calculating part: sets a
first starting point and a first ending point on the reference line
in the intermediate shape data; calculates a straight-line first
alignment axis that connects the first starting point and the first
ending point; sets a second starting point corresponding to the
first starting point on the reference line in the target shape
data; calculates a point on the reference line in the target shape
data, that is distant from the second starting point by a distance
equal to a length of the first alignment axis, as a second ending
point; calculates a straight-line second alignment axis that
connects the second starting point and the second ending point to
each other; overlaps the intermediate shape data and the target
shape data on each other such that the first alignment axis and the
second alignment axis are overlapped on each other in the state
where the first starting point and the second starting point match
with each other; and relatively rotates the intermediate shape data
relative to the target shape data centering the first alignment
axis and the second alignment axis overlapped on each other.
2. The deformation processing support system according to claim 1,
wherein the necessary deformation amount calculating part, after
overlapping the first alignment axis and the second alignment axis
on each other, parallel-translates the intermediate shape data in a
direction perpendicular to the first alignment axis overlapped on
the second alignment axis such that a section between the first
starting point and the first ending point of the reference line in
the intermediate shape data is brought into contact with a section
between the second starting point and the second ending point of
the reference line in the target shape data.
3. The deformation processing support system according to claim 1,
further comprising, as the intermediate shape data acquiring part:
a 3-D laser scanner that three-dimensionally measures a shape of
the overall work; a camera that shoots the reference line on the
work; a reference line shape data producing part that extracts the
reference line from a shot image by the camera to produce reference
line shape data; and an intermediate shape data producing part that
produces the intermediate shape data by synthesizing 3-D
measurement data by the 3-D laser scanner and the reference line
shape data with each other.
4. The deformation processing support system according to claim 1,
further comprising, as the intermediate shape data acquiring part:
a camera that shoots the work having the intermediate shape from
plural directions; and an intermediate shape data producing part
that produces the intermediate shape data based on plural pieces of
shot image data shot by the camera from the plural directions.
5. The deformation processing support system according to claim 1,
further comprising a contour chart producing part that produces a
contour chart based on the necessary deformation amount of each of
the plural positions on the work calculated by the necessary
deformation amount calculating part.
6. The deformation processing support system according to claim 1,
wherein plural reference lines are disposed by disposing grid lines
on the overall surface in the target shape data and on the overall
surface of the work.
7. A deformation processing support method of calculating a
necessary deformation amount necessary for deformation from an
intermediate shape of a work to a target shape thereof based on a
difference between the intermediate shape and the target shape in
deformation processing for the work, the deformation processing
support method comprising the steps of: acquiring target shape data
of the work having a reference line disposed on a surface thereof;
marking a reference line on the surface of the work before the
deformation processing is started; acquiring intermediate shape
data from the work having an intermediate shape and having the
reference line marked on the surface thereof, during the
deformation processing; overlapping the target shape data and the
intermediate shape data on each other by aligning the reference
lines relative to each other; and calculating the necessary
deformation amount for each of plural positions on the work having
the intermediate shape based on a difference between the target
shape data and the intermediate shape data overlapped on each
other; and as the overlapping of the target shape data and the
intermediate shape data on each other, setting a first starting
point and a first ending point on the reference line in the
intermediate shape data; calculating a straight-line first
alignment axis that connects the first starting point and the first
ending point; setting a second starting point corresponding to the
first starting point on the reference line in the target shape
data; calculating a point on the reference line in the target shape
data, that is distant from the second starting point by a distance
equal to a length of the first alignment axis, as a second ending
point; calculating a straight-line second alignment axis that
connects the second starting point and the second ending point to
each other; overlapping the intermediate shape data and the target
shape data on each other such that the first alignment axis and the
second alignment axis are overlapped on each other in the state
where the first starting point and the second starting point match
with each other; and relatively rotating the intermediate shape
data relative to the target shape data centering the first
alignment axis and the second alignment axis overlapped on each
other.
8. The deformation processing support method according to claim 7,
further comprising the step of after overlapping the first
alignment axis and the second alignment axis on each other,
parallel-translating the intermediate shape data in a direction
perpendicular to the first alignment axis overlapped on the second
alignment axis such that a section between the first starting point
and the first ending point of the reference line in the
intermediate shape data is brought into contact with a section
between the second starting point and the second ending point of
the reference line in the target shape data.
9. The deformation processing support method according to claim 7,
further comprising the steps of: three-dimensionally measuring a
shape of the overall work using a 3-D laser scanner; shooting the
reference line on the work using a camera; extracting the reference
line from a shot image by the camera to produce reference line
shape data; and producing the intermediate shape data by
synthesizing 3-D measurement data by the 3-D laser scanner and the
reference line shape data with each other.
10. The deformation processing support method according to claim 7,
further comprising the step of producing the intermediate shape
data based on plural pieces of shot image data on the work having
the intermediate shape shot by a camera from plural directions.
11. The deformation processing support method according to claim 7,
further comprising the step of producing a contour chart based on
the necessary deformation amount calculated for each of the plural
positions on the work.
12. The deformation processing support system according to claim 7,
wherein plural reference lines are disposed by disposing grid lines
on an overall surface in the target shape data and on an overall
surface of the work.
Description
TECHNICAL FIELD
[0001] The present invention relates to a deformation processing
support system and a deformation processing support method that
each support deformation processing for a work.
BACKGROUND ART
[0002] When a large work is deformation-processed, bending
processing is traditionally executed for plural times for the work
by using, for example, a press processing machine. The overall work
is deformation-processed into the target shape by executing the
bending processing at each of plural positions on the work.
[0003] The work after the deformation processing therefor comes to
an end is checked as to whether the work is finished into the
target shape, by lapping a wooden mold having a shape that
corresponds to the target shape on the work. The wooden mold is
divided into plural pieces because the work is large.
[0004] Otherwise, the work after the deformation processing
therefor comes to an end is checked as to its shape using a 3-D
measuring machine. For example, the shape of each of the plural
portions of the work is three-dimensionally measured using a 3-D
laser scanner. Plural pieces of partial shape data acquired by this
measurement are synthesized with each other into one piece to
produce overall shape data of the work as described in, for
example, Patent Document 1. The work after the deformation
processing therefor comes to an end is checked as to whether the
work is finished into the target shape based on the produced
overall shape data of the work.
PRIOR ART DOCUMENT
Patent Document
[0005] Patent Document 1: Japanese Laid-Open Patent Publication No.
11-65628
SUMMARY OF THE INVENTION
Problem to be Solved by the Invention
[0006] During the deformation processing for a work (such as, for
example, between one bending processing session and the succeeding
bending processing session), the deformation amount of the work
necessary for the deformation from an intermediate shape to the
target shape (a necessary deformation amount) such as, for example,
the necessary deformation amount for each of plural positions on
the work may be checked. In this case, the necessary deformation
amount necessary for deformation into the target shape can be
learned by lapping the wooden molds on the work having the
intermediate shape and checking any gap between each of the wooden
molds and the work. To execute this, the wooden molds each
corresponding to any one of the plural portions of the work however
need to be lapped on the work, and labor and time therefor are
necessary. When the shape of the work is complicated and large, the
number of the wooden molds becomes great, and much labor and much
time are necessary. The gaps each between a surface edge portion of
the wooden molds butting against the work and the work are visually
observable while the gaps each between the surface central portion
of the wooden mold and the work may be visually unobservable.
[0007] On the other hand, the necessary deformation amount for each
of the plural positions of the work necessary for deforming into
the target shape can be calculated by overlapping intermediate
shape data of the work during the deformation processing acquired
by a 3-D measuring machine and target shape data of the work on
each other and calculating the difference between these two pieces
of data.
[0008] A "best fit" technique is present as an approach of
overlapping the two pieces of shape data. The "best fit" is an
approach of detecting plural resembling points between the two
pieces of data (feature points) and overlapping the two pieces of
data on each other by aligning the two pieces of data relative to
each other using the resembling points each as a reference. For
example, the resembling point is a hole formed in the work, a
corner portion of the work, or a marker attached to the work.
[0009] When the curvature significantly differs between the
intermediate shape data of the work during the deformation
processing and the target shape data, the precision is degraded for
the overlapping of the two pieces of data on each other by the
"best fit". Otherwise, the overlapping itself may be unable. In the
case where no resembling point is present such as the case where no
hole is present in the work, where the outer edge of the work is
cut off (trimmed off) after the deformation processing comes to an
end, or where no marker can be attached to the work because any
marker obstacles the deformation processing, the "best fit" itself
cannot be executed. The precision is therefore low for the
calculation of the necessary deformation amount necessary for
deforming into the target shape at each of the plural positions on
the work, or the calculation is unable.
[0010] An object of the present invention is to highly precisely
calculate in a short time period the necessary deformation amount
of the work necessary for deforming into the target shape in the
deformation processing for the work.
Means for Solving Problem
[0011] To solve the technical object, according to an aspect of the
present invention, a deformation processing support system
calculating a necessary deformation amount necessary for
deformation from an intermediate shape of a work to a target shape
thereof based on the difference between the intermediate shape and
the target shape in deformation processing for the work is
provided, that includes:
[0012] a target shape data acquiring part that acquires target
shape data of the work having a reference line disposed on its
surface;
[0013] an intermediate shape data acquiring part that acquires
intermediate shape data from the work having the intermediate shape
and having a reference line marked on its surface, during the
deformation processing; and
[0014] a necessary deformation amount calculating part that
overlaps the target shape data and the intermediate shape data on
each other by aligning the reference lines relative to each other
and that calculates a necessary deformation amount for each of
plural positions on the work based on the difference between the
target shape data and the intermediate shape data overlapped on
each other, and of which
[0015] as the overlapping of the target shape data and the
intermediate shape data on each other, the necessary deformation
amount calculating part:
[0016] sets a first starting point and a first ending point on the
reference line in the intermediate shape data;
[0017] calculates a straight-line first alignment axis that
connects the first starting point and the first ending point to
each other;
[0018] sets a second starting point corresponding to the first
starting point on the reference line in the target shape data;
[0019] calculates a point on the reference line in the target shape
data, that is distant from the second starting point by a distance
equal to the length of the first alignment axis, as a second ending
point;
[0020] calculates a straight-line second alignment axis that
connects the second starting point and the second ending point to
each other;
[0021] overlaps the intermediate shape data and the target shape
data on each other such that the first alignment axis and the
second alignment axis are overlapped on each other in the state
where the first starting point and the second starting point match
with each other; and
[0022] relatively rotates the intermediate shape data relative to
the target shape data centering the first alignment axis and the
second alignment axis overlapped on each other.
[0023] According to another aspect of the present invention, a
deformation processing support method of calculating a necessary
deformation amount necessary for deformation from an intermediate
shape of a work to a target shape thereof based on the difference
between the intermediate shape and the target shape in deformation
processing for the work is provided, that includes the steps
of:
[0024] acquiring target shape data of the work having a reference
line disposed on its surface;
[0025] marking a reference line on the surface of the work before
the deformation processing is started;
[0026] acquiring intermediate shape data from the work having an
intermediate shape and having the reference line marked on the
surface thereof, during the deformation processing;
[0027] overlapping the target shape data and the intermediate shape
data on each other by aligning the reference lines relative to each
other; and
[0028] calculating a necessary deformation amount for each of
plural positions on the work having the intermediate shape based on
the difference between the target shape data and the intermediate
shape data overlapped on each other; and, as the overlapping of the
target shape data and the intermediate shape data on each
other,
[0029] setting a first starting point and a first ending point on
the reference line in the intermediate shape data;
[0030] calculating a straight-line first alignment axis that
connects the first starting point and the first ending point to
each other;
[0031] setting a second starting point corresponding to the first
starting point on the reference line in the target shape data;
[0032] calculating a point on the reference line in the target
shape data, that is distant from the second starting point by a
distance equal to the length of the first alignment axis, as a
second ending point;
[0033] calculating a straight-line second alignment axis that
connects the second starting point and the second ending point to
each other;
[0034] overlapping the intermediate shape data and the target shape
data on each other such that the first alignment axis and the
second alignment axis are overlapped on each other in the state
where the first starting point and the second starting point match
with each other; and
[0035] relatively rotating the intermediate shape data relative to
the target shape data centering the first alignment axis and the
second alignment axis overlapped on each other.
Effect of the Invention
[0036] According to the present invention, the necessary
deformation amount of a work necessary for deforming the work into
the target shape in deformation processing for the work can be
highly precisely calculated in a short time period.
BRIEF DESCRIPTION OF DRAWINGS
[0037] FIG. 1 is a schematic diagram of the configuration of a
deformation processing support system according to an embodiment of
the present invention.
[0038] FIG. 2 is a block diagram of the deformation processing
support system.
[0039] FIG. 3 is a diagram of target shape data.
[0040] FIG. 4 is a diagram of 3-D measurement data.
[0041] FIG. 5 is a diagram of a work before deformation processing
is started.
[0042] FIG. 6 is a diagram of a shot image by a camera.
[0043] FIG. 7 is a diagram for explaining production of
intermediate shape data.
[0044] FIG. 8 is a diagram of overlapping of the intermediate shape
data on the target shape data.
[0045] FIG. 9A is a diagram of a procedure for overlapping the
intermediate shape data on the target shape data.
[0046] FIG. 9B is a diagram of the procedure for overlapping the
intermediate shape data on the target shape data, continued from
that in FIG. 9A.
[0047] FIG. 9C is a diagram of the procedure for overlapping the
intermediate shape data on the target shape data, continued from
that in FIG. 9B.
[0048] FIG. 9D is a diagram of the procedure for overlapping the
intermediate shape data on the target shape data, continued from
that in FIG. 9C.
[0049] FIG. 9E is a diagram of the procedure for overlapping the
intermediate shape data on the target shape data, continued from
that in FIG. 9D.
[0050] FIG. 10 is a diagram of a contour chart.
[0051] FIG. 11A is a diagram for explaining a parallel translation
process of the intermediate shape data.
[0052] FIG. 11B is a diagram of the intermediate shape data after
the parallel translation thereof.
[0053] FIG. 12 is a flowchart of an example of the flow of
operations of the deformation processing support system.
[0054] FIG. 13 is a flowchart of an overlapping process for the
intermediate shape data on the target shape data.
MODES FOR CARRYING OUT THE INVENTION
[0055] An aspect of the present invention is a deformation
processing support system calculating a necessary deformation
amount necessary for deformation from an intermediate shape of a
work to a target shape thereof based on the difference between the
intermediate shape and the target shape in deformation processing
for the work, that includes a target shape data acquiring part that
acquires target shape data of the work having a reference line
disposed on its surface, an intermediate shape data acquiring part
that acquires intermediate shape data from the work having the
intermediate shape and having a reference line marked on its
surface, during the deformation processing, and a necessary
deformation amount calculating part that overlaps the target shape
data and the intermediate shape data on each other by aligning the
reference lines relative to each other and that calculates the
necessary deformation amount for each of plural positions on the
work based on the difference between the target shape data and the
intermediate shape data overlapped on each other, and of which, as
the overlapping of the target shape data and the intermediate shape
data on each other, the necessary deformation amount calculating
part sets a first starting point and a first ending point on the
reference line in the intermediate shape data, calculates a
straight-line first alignment axis that connects the first starting
point and the first ending point to each other, sets a second
starting point corresponding to the first starting point on the
reference line in the target shape data, calculates a point on the
reference line in the target shape data, that is distant from the
second starting point by a distance equal to the length of the
first alignment axis, as a second ending point, calculates a
straight-line second alignment axis that connects the second
starting point and the second ending point to each other, overlaps
the intermediate shape data and the target shape data on each other
such that the first alignment axis and the second alignment axis
are overlapped on each other in the state where the first starting
point and the second starting point match with each other, and
relatively rotates the intermediate shape data relative to the
target shape data centering the first alignment axis and the second
alignment axis overlapped on each other.
[0056] According to this aspect, the necessary deformation amount
for a work necessary for deforming the work into the target shape
in deformation processing for the work can be highly precisely
calculated in a short time period.
[0057] After overlapping the first alignment axis and the second
alignment axis on each other, the necessary deformation amount
calculating part may parallel-translate the intermediate shape data
in the direction perpendicular to the first alignment axis
overlapped on the second alignment axis such that a section between
the first starting point and the first ending point of the
reference line in the intermediate shape data is brought into
contact with a section between the second starting point and the
second ending point of the reference line in the target shape
data.
[0058] The deformation processing support system may include, as
the intermediate shape data acquiring part, a 3-D laser scanner
that three-dimensionally measures the shape of the overall work, a
camera that shoots the reference line on the work, a reference line
shape data producing part that produces reference line shape data
by extracting the reference line from a shot image by the camera,
and an intermediate shape data producing part that produces the
intermediate shape data by synthesizing 3-D measurement data by the
3-D laser scanner and the reference line shape data with each
other.
[0059] Otherwise, the deformation processing support system may
include, as the intermediate shape data acquiring part, a camera
that shoots the work having an intermediate shape from plural
directions, and an intermediate shape data producing part that
produces the intermediate shape data based on plural pieces of shot
image data shot by the camera from the plural directions.
[0060] The deformation processing support system may include a
contour chart producing part that produces a contour chart based on
the necessary deformation amount for each of the plural positions
on the work calculated by the necessary deformation amount
calculating part. A worker can variously study to finish the work W
into the target shape by referring to the contour chart. As a
result, the work W is highly efficiently finished into the target
shape in a short time period.
[0061] Plural reference lines may be disposed by disposing grid
lines on the overall surface in the target shape data and on the
overall surface of the work. The target shape data and the
intermediate shape data are thereby overlapped on each other by
alignment using the reference lines at a position at which no more
bending processing can be executed for the reason such as, for
example, a small thickness and the deformation amount can thereby
be calculated that is necessary for deforming into the target shape
at each of the other positions on the work. The degree of freedom
is therefore improved concerning the manner of the deformation
processing for the work compared to the case where the reference
line is disposed in a portion of the surface of each of the target
shape data and the work.
[0062] Another aspect of the present invention is a deformation
processing support method of calculating the necessary deformation
amount necessary for deformation from an intermediate shape of a
work to a target shape thereof based on the difference between the
intermediate shape and the target shape in deformation processing
for the work, that includes the steps of acquiring target shape
data of the work having a reference line disposed on its surface,
marking a reference line on the surface of the work before the
deformation processing is started, acquiring intermediate shape
data from the work having the intermediate shape and having the
reference line marked on its surface during the deformation
processing, overlapping the target shape data and the intermediate
shape data on each other by aligning the reference lines relative
to each other, and calculating the necessary deformation amount for
each of plural positions on the work having the intermediate shape
based on the difference between the target shape data and the
intermediate shape data overlapped on each other, and, as the
overlapping of the target shape data and the intermediate shape
data on each other, setting a first starting point and a first
ending point on the reference line in the intermediate shape data,
calculating a straight-line first alignment axis that connects the
first starting point and the first ending point to each other,
setting a second starting point corresponding to the first starting
point on the reference line in the target shape data, calculating a
point on the reference line in the target shape data, that is
distant from the second starting point by a distance equal to the
length of the first alignment axis, as a second ending point,
calculating a straight-line second alignment axis that connects the
second starting point and the second ending point to each other,
overlapping the intermediate shape data and the target shape data
on each other such that the first alignment axis and the second
alignment axis overlap on each other in the state where the first
starting point and the second starting point match with each other,
and relatively rotating the intermediate shape data relative to the
target shape data centering the first alignment axis and the second
alignment axis overlapped on each other.
[0063] According to the other aspect, the necessary deformation
amount for the work necessary for deforming the work into the
target shape in the deformation processing for the work can be
highly precisely calculated in a short time period.
[0064] After the first alignment axis and the second alignment axis
are overlapped on each other, the intermediate shape data may be
parallel-translated in the direction perpendicular to the first
alignment axis overlapped on the second alignment axis such that a
section between the first starting point and the first ending point
of the reference line in the intermediate shape data is brought
into contact with a section between the second starting point and
the second ending point of the reference line in the target shape
data.
[0065] To acquire the intermediate shape data, the intermediate
shape data may be produced by three-dimensionally measuring the
shape of the overall work using the 3-D laser scanner, shooting the
reference line on the work using the camera, producing the
reference line shape data by extracting the reference line from the
shot image by the camera, and synthesizing the three-dimensionally
measured data by the 3-D laser scanner and the reference line shape
data with each other.
[0066] Otherwise, to acquire the intermediate shape data, the
intermediate shape data may be produced based on the plural pieces
of shot image data on the work having the intermediate shape shot
from the plural directions by the camera.
[0067] A contour chart may be produced based on the necessary
deformation amount calculated for each of the plural positions on
the work. A worker can variously study to finish the work W into
the target shape by referring to the contour chart. As a result,
the work W is highly efficiently finished into the target shape in
a short time period.
[0068] Plural reference lines may be disposed by disposing grid
lines on the overall surface in the target shape data and on the
overall surface of the work. The target shape data and the
intermediate shape data are thereby overlapped on each other by
alignment using the reference lines at a position at which no more
bending processing can be executed for the reason such as, for
example, a small thickness and the deformation amount can thereby
be calculated that is necessary for deforming into the target shape
for each of the other positions on the work. The degree of freedom
is improved concerning the manner of the deformation processing for
the work compared to the case where the reference line is disposed
in a portion of the surface of each of the target shape data and
the work.
[0069] An embodiment of the present invention will be described
below with reference to the drawings.
[0070] FIG. 1 schematically depicts the configuration of a
deformation processing support system according to an embodiment of
the present invention. FIG. 2 is a block diagram of the deformation
processing support system.
[0071] The overview of the deformation processing support system 10
according to this embodiment depicted in FIG. 1 and FIG. 2 will be
described. The deformation processing support system 10 according
to this embodiment is a system that supports deformation processing
for a work W in which plural bending processing sessions are
executed for the work W. For example, describing the details later,
the deformation processing support system 10 is a system that
calculates a necessary deformation amount necessary for deformation
from an intermediate shape to a target shape based on the
intermediate shape (data) of the work W during the deformation
processing and the target shape (data) of the work W.
[0072] In this embodiment, the work W before the deformation
processing is started has a flat-plate shape. The work W is
produced from an aluminum material. In this embodiment, the plural
bending processing (the deformation processing) sessions for the
work W are executed by a press processing machine 12.
[0073] The press processing machine 12 presses downward the work W
at each of plural positions of the work W using an upper side punch
12a and thereby executes the bending processing for the position.
The overall work W is finally deformation-processed into the target
shape by sequentially executing the bending processing for the
plural positions of the work W.
[0074] In this deformation processing for the work W, during the
deformation processing at a position or during a time period
between the end of the bending processing for a position and the
start of the bending processing for another position, a worker may
desire to know the deformation amount of the work W necessary for
deformation from the intermediate shape to the target shape, that
is, the necessary deformation amount for each of the plural
positions on the work W. The deformation processing support system
10 of this embodiment calculates the deformation amount for each of
the plural positions on the work W necessary for deformation from
the intermediate shape to the target shape.
[0075] The deformation processing support system 10 of this
embodiment includes a 3-D laser scanner 14 that measures the shape
(a 3-D shape) of the work W during the deformation processing, a
camera 16 that shoots the work W during the deformation processing,
and a computing apparatus 18.
[0076] The 3-D laser scanner 14 is a non-contact 3-D measuring
machine that scans the overall work W, that measures the distance
to the work W based on a reflected light beam from the work W, and
that three-dimensionally measures the shape of the work W based on
the measured distance. The 3-D laser scanner 14 three-dimensionally
measures the overall work W having an intermediate shape after the
bending processing is executed for the work W for a predetermined
times or at an optional timing designated by a worker, that is,
when the upper side punch 12a of the press processing machine 12 is
away from the work W. The 3-D measurement data thereof is sent to
the computing apparatus 18.
[0077] In this embodiment, the camera 16 partially shoots the work
W. The camera 16 shoots, for example, a region R of the work W
positioned immediately under the upper side punch 12a of the press
processing machine 12. When the upper side punch 12a of the press
processing machine 12 is away from the work W, the camera 16 shoots
the region R of the work W having the intermediate shape
immediately after being bending-processed by the upper side punch
12a or immediately before being bending-processed thereby, as a
shot region R. The shot image (data) by the camera 16 is sent to
the computing apparatus 18. Describing the reason later, it is
preferred that the camera 16 have a sensitivity that is as high as
possible.
[0078] As depicted in FIG. 2, the computing apparatus 18 is
connected to the press processing machine 12, the 3-D laser scanner
14, and the camera 16. When the computing apparatus 18 receives a
signal (a bending processing end signal) indicating that the upper
side punch 12a leaves the work W, from the press processing machine
12, the computing apparatus 18 sends a measurement execution signal
to the 3-D laser scanner 14 and sends a shooting execution signal
to the camera. The computing apparatus 18 acquires the 3-D
measurement data of the work W having the intermediate shape, from
the 3-D laser scanner 14 executing the 3-D measurement, and
acquires the shot image data of the work W having the intermediate
shape, from the camera 16 executing the shooting. The computing
apparatus 18 calculates the necessary deformation amount necessary
for deformation from the intermediate shape to the target shape for
each of the plural positions on the work W based on those pieces of
data. In this embodiment, the computing apparatus 18 is configured
to output the calculated necessary deformation amount to the worker
through an output device 20 (such as, for example, a display). The
computing apparatus 18 will hereinafter be described in detail.
[0079] As depicted in FIG. 2, the computing apparatus 18 includes a
target shape data acquiring part 50 acquiring the target shape data
of the work W, a 3-D measurement data acquiring part 52 acquiring
the 3-D measurement data of the work W from the 3-D laser scanner
14, a shot image acquiring part 54 acquiring the shot image of the
work W from the camera 16, an image processing part 56
image-processing the acquired shot image, a reference line shape
data producing part 58 producing the reference line shape data from
the image-processed shot image, an intermediate shape data
producing part 60 producing the intermediate shape data based on
the 3-D measurement data and the reference line shape data, a
necessary deformation amount calculating part 62 calculating the
necessary deformation amount of the work W necessary for
deformation from the intermediate shape to the target shape, and a
contour chart producing part 64 producing a contour chart based on
the calculated necessary deformation amount. For example, the
computing apparatus 18 is a computer including a CPU and a storage
medium, and functions as the 3-D measurement data acquiring part
52, the shot image acquiring part 54, the image processing part 56,
the reference line shape data producing part 58, the intermediate
shape data producing part 60, the necessary deformation amount
calculating part 62, and the contour chart producing part 64 by
operations of the CPU in accordance with a program in the storage
medium.
[0080] As depicted in FIG. 3, the target shape data acquiring part
50 of the computing apparatus 18 acquires the target shape data Ft
of the work W. The target shape data Ft is 3-D CAD data indicating,
for example, the shape of the finished product of the work W, that
is, the shape acquired after the deformation processing comes to an
end. The target shape data acquiring part 50 acquires the 3-D CAD
data from, for example, a CAD apparatus (not depicted) connected to
the computing apparatus 18. An X-direction, a Y-direction, and a
Z-direction depicted in FIG. 3 respectively indicate a width
direction, a depth direction, and a thickness direction of the work
W when the work W has a flat-plate shape.
[0081] Describing the reason later, the target shape data Ft of the
work W includes a reference line CLt on the surface Fts thereof
(the surface corresponding to the surface Ws of the actual work W
pressed by the upper side punch 12a of the press processing machine
12). In this embodiment, the plural reference lines CLt are
arranged in a grid form.
[0082] As depicted in FIG. 4, the 3-D measurement data acquiring
part 52 of the computing apparatus 18 acquires the 3-D measurement
data Fm of the work W from the 3-D laser scanner 14. The 3-D
measurement data Fm is, for example, point group data.
[0083] As depicted in FIG. 5, describing the reason later, a
reference line CL is marked on the surface Ws of the actual work W
pressed by the upper side punch 12a of the press processing machine
12. In this embodiment, the plural reference lines CL are arranged
in a grid form. For example, the plural reference lines CL are
scribed lines maintained during the deformation processing without
being erased.
[0084] As depicted in FIG. 4, the 3-D measurement data Fm of the
work W measured by the 3-D laser scanner 14 however does not have
the plural reference lines CL appearing therein. The 3-D laser
scanner 14 cannot detect the grid lines (the plural reference lines
CL) because the recesses and the protrusions of the grid lines
marked on the surface Ws of the work W are small, and the 3-D
measurement data Fm does substantially not have the grid lines
appearing therein. To cope with this, describing the reason later,
the camera 16 partially shoots the work W.
[0085] The plural reference lines CLt arranged in the grid form on
the surface Fts in the target shape data Ft and the plural
reference lines CL arranged in the grid form on the surface Ws of
the work W substantially correspond to each other. For example, the
pitch of the reference lines on the work W is set to be small
compared to the pitch of the reference lines in the target shape
data Ft taking into consideration the stretch generated when the
work W is deformation-processed from the flat-plate shape to the
target shape.
[0086] As depicted in FIG. 6, the shot image acquiring part 54 of
the computing apparatus 18 acquires the shot image Pr of the work W
from the camera 16. In this embodiment, the camera 16 shoots the
shot region R immediately under the upper side punch 12a of the
press processing machine 12 as depicted in FIG. 1 and the shot
image Pr is therefore a partial shot image of the work W. As
depicted in FIG. 6, the shot image Pr shows the plural reference
lines CL in the grid form marked on the surface Ws of the work
W.
[0087] The image processing part 56 of the computing apparatus 18
image-processes the shot image Pr to extract the reference lines CL
shown in the shot image Pr by the camera 16. The image processing
part 56 executes, for example, adjustment of the brightness and the
contrast, the contour enhancement correction, and the like for the
shot image Pr. The adjustment of the parameters such as the
brightness and the contrast in the image processing may be set to
be executable by the worker through an input device 22 (such as,
for example, a keyboard) connected to the computing apparatus 18.
To realize this, the computing apparatus 18 outputs the shot image
Pr by the camera 16 to the worker through the output device 20.
[0088] As depicted in FIG. 7, the reference line shape data
producing part 58 of the computing apparatus 18 extracts the
reference line CL shown in the image-processed shot image Pr by the
camera 16 and thereby produces the reference line shape data Fcl.
The reference line shape data Fcl is 3-D shape data and is produced
from the 2-D shot image Pr based on the positional relation between
the camera 16 and the shot region R thereof. To highly precisely
produce the reference line shape data Fcl, the plural cameras 16
may be used. The plural cameras 16 each shoot the shot region R
common thereto from a direction different from that of each other,
and the 3-D reference line shape data Ed is produced from the
plural shot images whose shooting directions are each different
from each other.
[0089] As depicted in FIG. 7, the intermediate shape data producing
part 60 of the computing apparatus 18 synthesizes the 3-D
measurement data Fm acquired from the 3-D laser scanner 14 by the
3-D measurement data acquiring part 52 and the reference line shape
data Fcl with each other. The shape data (the intermediate shape
data) Fin of the work W having the intermediate shape and partially
including reference line CLin on a surface Fins is produced by the
above synthesis. The reference line shape data Fcl is arranged on
the intermediate shape data Fin to correspond to the relative
position of the shot region R by the camera 16 relative to the
overall work W, based on the relative positional relation between
the 3-D laser scanner 14 and the camera 16.
[0090] The necessary deformation amount calculating part 62 of the
computing apparatus 18 calculates the necessary deformation amount
necessary for deformation from the intermediate shape to the target
shape for each of the plural positions on the work W based on the
target shape data Ft obtained by the target shape data acquiring
part 50 and the intermediate shape data Fin produced by the
intermediate shape data producing part 60.
[0091] To describe, as depicted in FIG. 8, the necessary
deformation amount calculating part 62 aligns the reference line
CLin in the intermediate shape data Fin and the corresponding
reference line CLt in the target shape data Ft relative to each
other and thereby executes a process of overlapping the
intermediate shape data Fin on the target shape data Ft (an
overlapping process).
[0092] To align the reference line CLin in the intermediate shape
data Fin and the corresponding reference line CLt in the target
shape data Ft relative to each other, each of the plural reference
lines CL on the work W and each of the reference lines CLt in the
target shape data Ft are configured to be distinguishable from each
other. For example, the reference lines are different in the
thickness, the shape, the color (such as, for example, a dotted
line) and the like. For example, a reference symbol is attached to
each of the reference lines (in the case of the work W, a character
such as a digit or an alphabet, or a symbol is marked). The
reference line CLin in the intermediate shape data Fin and the
corresponding reference line CLt in the target shape data Ft are
thereby identified.
[0093] Instead, when the output device 20 is a display, the worker
may instruct the reference line CLt in the target shape data Ft
corresponding to the reference line CLin in the intermediate shape
data Fin to the computing apparatus 18 through the input device 22,
on the screen of the display.
[0094] For supplement, the shape of the reference line CLin in the
intermediate data Fin and the shape of the corresponding reference
line CLt in the target shape data Ft are different from each other
to be exact. The overall reference line CLin in the intermediate
shape data Fin and the overall corresponding reference line CLt in
the target shape data Ft therefore do not completely overlap on
each other.
[0095] The alignment of the reference line CLin in the intermediate
shape data Fin and the reference line CLt in the target shape data
Ft with each other will hereinafter be described taking an example
and with reference to FIGS. 9A to 9E.
[0096] FIG. 9A depicts a cross-section of the intermediate shape
data Fin taken by cutting along a plane along the one reference
line CLin on the surface Fins (that is, including the reference
line CLin), and a cross-section of the target shape data Ft taken
by cutting along a plane along the corresponding reference line CLt
on the surface Fts (that is, including the reference line CLt). The
cross-sections of the pieces of shape data are depicted to
facilitate the understanding and these cross-sections are not
necessary for the alignment of the reference lines.
[0097] As depicted in FIG. 9A, the reference line CLin in the
intermediate shape data Fin and the reference line CLt in the
target shape data Ft are different in the shape. The reference line
CLin in this case is a reference line passing through a processing
region (processing scheduled region) WR scheduled to be pressed by
the upper side punch 12a of the press processing machine 12 from
now, that is, the processing scheduled region WR for which the
difference between the target shape and the intermediate shape
needs to be learned for this processing.
[0098] To align the reference line CLin in the intermediate shape
data Fin and the corresponding reference line CLt in the target
shape data Ft differing in the shape as depicted in FIG. 9A with
each other, a first starting point SP1 and a first ending point EP1
are first set on the reference line CLin in the intermediate shape
data Fin as depicted in FIG. 9B.
[0099] It is preferred that the first starting point SP1 and the
first ending point EP1 be set such that a section between the first
starting point SP1 and the first ending point EP1 on the reference
line CLin in the intermediate shape data Fin is included in a
region for which the difference between the target shape and the
actual intermediate shape needs to be learned (such as, for
example, the processing scheduled region WR).
[0100] The determination of the reference line CLin in the
intermediate shape data Fin to be aligned and the setting of the
first starting point SP1 and the first ending point EP1 may be
executed by the worker through the input device 22 by urging the
worker using the computing apparatus 18 through the output device
20 for the determination and the setting.
[0101] Instead, the worker designates the position on the work W to
be next pressed by the upper side punch 12a (the processing
scheduled region WR) through the input device 22. The worker may
designate, for example, a region in the intermediate shape data Fin
displayed on the output device 20 as the processing scheduled
region WR through the input device 22. The computing apparatus 18
may determine the reference line CLin passing through the
processing scheduled region WR and set the first starting point SP1
and the first ending point EP1 to be included in the processing
scheduled region WR, based on the designation.
[0102] As depicted in FIG. 9B, a straight-line first alignment axis
PA1 connecting the first starting point SP1 and the first ending
point EP1 is next calculated. The first alignment axis PA1 is a
line. The computing apparatus 18 calculates the direction for the
first alignment axis PA1 to extend in and the length thereof based
on, for example, the coordinates of the first starting point SP1
and the coordinates of the first ending point EP1.
[0103] As depicted in FIG. 9C, a second starting point SP2
corresponding to the first starting point SP1 is set on the
reference line CLt in the target shape data Ft. The second starting
point SP2 may be set by the worker through the input device 22. The
worker designates, for example, a point on the reference line CLt
in the target shape data Ft displayed on the output device 20,
through the input device 22 and the second starting point SP2 is
thereby set.
[0104] Instead, in the case where the first starting point SP1 is
set at an intersection point of the plural reference lines CLin,
the computing apparatus 18 may identify the two reference lines
CLin in the intermediate shape data Fin that intersect each other
to form the first starting point SP1, may identify the two
reference lines CLt in the target shape data Ft corresponding to
the identified two reference lines CLin, and may set the
intersection of the identified two reference lines CLt as the
second starting point SP2.
[0105] When the second starting point SP2 is set, the computing
apparatus 18 calculates the second ending point EP2 based on the
length D of the first alignment axis PA1 and the second starting
point SP2. The second ending point EP2 is set on the reference line
CLt distant from the second starting point SP2 by the distance D.
The second ending point EP2 is an intersection formed by a circle
centering the second starting point SP2 and having a radius D, and
the reference line CLt, and can geometrically be calculated.
[0106] When the second ending point EP2 is calculated, the
computing apparatus 18 calculates the straight-line second
alignment axis PA2 connecting the second starting point SP2 and the
second ending point EP2 to each other as depicted in FIG. 9D. The
second alignment axis PA2 is a line having the length equal to the
length D of the first alignment axis PA1. For example, the
computing apparatus 18 calculates the direction for the second
alignment axis PA2 to extend in and the length thereof based on the
coordinates of the second starting point SP2 and the coordinates of
the second ending point EP2.
[0107] When the second alignment axis PA2 is calculated, the
computing apparatus 18 aligns the first alignment axis PA1 and the
second alignment axis PA with each other and thereby overlaps the
intermediate shape data Fin and the target shape data Ft on each
other as depicted in FIG. 9E. For example, in the state where the
first starting point SP1 and the second starting point SP2 match
with each other, the first alignment axis PA1 and the second
alignment axis PA2 are aligned relative to each other to be
overlapped on each other. The first alignment axis PA1 and the
second alignment axis PA2 each have the length D equal to that of
each other and therefore can completely be overlapped on each
other. The first alignment axis PA1 and the second alignment axis
PA2 are highly precisely aligned relative to each other as above
and the reference line CLin in the intermediate shape data Fin and
the reference line CL in the target shape data Ft are thereby
highly precisely aligned relative to each other.
[0108] Even when the first alignment axis PA1 and the second
alignment axis PA2 are completely overlapped on each other, as
depicted in FIG. 9E, the reference lines CLin and CLt are not
always overlapped on each other. The computing apparatus 18 is
therefore configured to execute the best fit process by rotating
the intermediate shape data Fin (the reference line CLin) centering
the first alignment axis PA1 overlapped on the second alignment
axis PA2. This best fit process aligns the reference lines CLin and
CLt relative to each other such that the section between the first
starting point SP1 and the first ending point EP1 of the reference
line CLin in the intermediate shape data Fin and the section
between the second starting point SP2 and the second ending point
EP2 of the reference line CLt in the target shape data Ft
substantially match with each other in the 3-D space. The phrase
"to substantially match" as used herein refers to "to completely
match" or "to match to the extent that a difference is present and
the difference is in an acceptable range".
[0109] When the intermediate shape data Fin are properly overlapped
on the target shape data Ft by aligning their reference lines CLin
and CLt relative to each other, the necessary deformation amount
calculating part 62 calculates the necessary deformation amount
necessary deforming from the intermediate shape to the target shape
for each of the plural positions on the work W.
[0110] For example, as depicted in FIG. 9E, the necessary
deformation amount calculating part 62 calculates the distance
between each of the plural positions in the intermediate shape data
Fin and the corresponding position in the target shape data Ft as
the necessary deformation amount necessary for deforming into the
target shape for the corresponding position on the work W based on
the difference between the intermediate shape data Fin and the
target shape data Ft overlapped on each other.
[0111] As depicted in FIG. 10, the contour chart producing part 64
of the computing apparatus 18 produces a contour chart (a contour
plot) based on the necessary deformation amount necessary for
deforming into the target shape for each of the plural positions on
the work W calculated by the necessary deformation amount
calculating part 62. In the contour chart, a portion whose
necessary deformation amount is zero is represented by a height of
zero, that is, the height of the surface Fts in the target shape
data Ft is zero. In the contour chart, a portion of the work W
whose necessary deformation amount is larger is represented by a
higher level. The produced contour chart is output to the worker
through the output device 20. The worker can variously study to
finish the work W into the target shape, by referring to the
contour chart. As a result, the work W can be highly efficiently
finished into the aimed shape in a short time period.
[0112] When the intermediate shape data Fin is overlapped on the
target shape data Ft as depicted in FIG. 9E, in the processing
scheduled region WR, the surface Fins in the intermediate shape
data Fin pressed by the upper side punch 12a may be positioned on
the counter-upper side punch side (on the lower side in FIG. 9E)
relative to the surface Fts in the target shape data Ft. The
surface Fts in the target shape data Ft may be present between the
surface Fins in the intermediate shape data Fin scheduled to be
pressed by the upper side punch 12a and the upper side punch
12a.
[0113] In this case, in the contour chart, the processing scheduled
region WR appears as a region whose necessary deformation amount
necessary for deformation from the intermediate shape to the target
shape is a negative value. It is therefore difficult for a worker,
especially an unexperienced worker to determine how the processing
scheduled region WR is pressed even when the worker refers to the
contour chart.
[0114] The computing apparatus 18 is therefore configured to
execute the following processes when the region whose necessary
deformation amount is a negative value is present in the contour
chart.
[0115] As depicted in FIG. 11A, a perpendicular line PL relative to
the first and the second alignment axes PA1 and PA2 overlapped on
each other to align the reference line CLin the intermediate shape
data Fin and the target shape data Ft relative to each other is
calculated. The perpendicular line PL, the section between the
first starting point SP1 and the first ending point EP1 of the
reference line CLin, and the section between the second starting
point S2 and the second ending point EP2 of the reference line CLt
are present on a substantially same plane.
[0116] The computing apparatus 18 parallel-translates the
intermediate shape data Fin in the direction for the perpendicular
line PL to extend in. For example, the computing apparatus 18
relatively parallel-translates the intermediate shape data Fin
relative to the target shape data Ft such that the section between
the first starting point SP1 and the first ending point EP1 of the
reference line CLin in the intermediate shape data Fin is brought
into contact with the section between the second starting point SP2
and the second ending point EP2 of the reference line CLt in the
target shape data Ft. For example, the maximal distance dHmax
between the reference line CLin in the intermediate shape data Fin
and the reference line CLt in the target shape data Ft is
calculated and the intermediate shape data Fin is
parallel-translated by the calculated distance.
[0117] The parallel translation process for the intermediate shape
data Fin relative to the target shape data Ft causes the surface
Fins in the intermediate shape data Fin scheduled to be pressed by
the upper side punch 12a to be positioned on the upper side punch
side (on the upper side in FIG. 11B) relative to the surface Fts in
the target shape data Ft in the processing scheduled region WR as
depicted in FIG. 11B. In the contour chart, the processing
scheduled region WR appears as a region whose necessary deformation
amount is a positive value. As a result, determination is
facilitated for the worker as to how the processing scheduled
region WR of the work is pressed based on the contour chart.
[0118] An example of the flow of the operations of the computing
apparatus 18 of the deformation processing support system 10
described so far will hereinafter be described with reference to a
flowchart depicted in FIG. 12.
[0119] At step S100, the computing apparatus 18 of the deformation
processing support system 10 acquires the target shape data Ft of
the work W to be deformation-processed as depicted in FIG. 3.
[0120] At step S110, the computing apparatus 18 acquires the 3-D
measurement data Fm as depicted in FIG. 4 from the 3-D laser
scanner 14 that already executes the 3-D measurement for the work W
having the intermediate shape.
[0121] At step S120, the computing apparatus 18 acquires the
partial shot image Pr of the work Was depicted in FIG. 6 from the
camera 16 that already partially shoots the work W having the
intermediate shape.
[0122] At step S130, the computing apparatus 18 image-processes the
shot image Pr by the camera 16 acquired at step S120.
[0123] At step S140, the computing apparatus 18 extracts the
intersecting lines CL (that is, the first and the second reference
lines intersecting each other) from the image-processed shot image
Pr and produces the reference line shape data Fcl thereof.
[0124] At step S150, as depicted in FIG. 7, the computing apparatus
18 synthesizes the 3-D measurement data Fm of the work W having the
intermediate shape acquired at step S110 and the reference line
shape data Fcl produced at step S140 with each other to produce the
intermediate shape data Fin.
[0125] At step S160, the computing apparatus 18 executes the
overlapping process of overlapping the intermediate shape data Fin
produced at step S150 on the target shape data Ft acquired at step
S100.
[0126] An example of the flow of the overlapping process will be
described with reference to a flowchart depicted in FIG. 13.
[0127] At step S161, the computing apparatus 18 calculates the
first alignment axis PA1 for the reference line CLin in the
intermediate shape data Fin as depicted in FIG. 9B to align the
reference line CLin in the intermediate shape data Fin and the
corresponding reference line CLt in the target shape data Ft
relative to each other.
[0128] At step S162, as depicted in FIG. 9D, the computing
apparatus 18 calculates the second alignment axis PA2 for the
reference line CLt in the target shape data Ft.
[0129] At step S163, the computing apparatus 18 aligns the first
alignment axis PA1 calculated at step S161 and the second alignment
axis PA2 calculated at step S162 relative to each other and, as
depicted in FIG. 9E, thereby overlaps the intermediate shape data
Fin on the target shape data Ft (executes the best fit
process).
[0130] At step S164, the computing apparatus 18 calculates the
necessary deformation amount necessary for deformation from the
intermediate shape to the target shape for each of the plural
positions on the work W based on the difference between the
intermediate shape data Fin and the target shape data Ft overlapped
on each other.
[0131] At step S165, the computing apparatus 18 produces the
contour chart as depicted in FIG. 10 based on the necessary
deformation amount calculated at step S164.
[0132] At step S166, the computing apparatus 18 determines whether
any region whose necessary deformation amount is a negative value
is not present in the contour chart produced at step S166. When the
computing apparatus 18 determines that no such region is present,
the flow advances to step S170.
[0133] On the other hand, when the computing apparatus 18
determines that a region whose necessary deformation amount is a
negative value is present in the contour chart, at step S167, the
computing apparatus 18 parallel-translates the intermediate shape
data Fin relative to the target shape data Ft as depicted in FIG.
11B. The surface Fins in the intermediate shape data Fin is thereby
brought into contact with the surface Ft in the target shape data
Ft. Returning back to step S164, the necessary deformation amount
is again calculated based on the intermediate shape data Fin and
the target shape data Ft overlapped on each other after the
parallel translation. At step S165, the contour chart is again
produced based on the necessary deformation amount that is again
calculated.
[0134] When the contour chart is produced, as depicted in FIG. 12,
at step S170, the computing apparatus 18 outputs the contour chart
produced at step S165 to the worker through the output device 20
depicted in FIG. 1.
[0135] According to this embodiment, in the deformation processing
for the work W, the necessary deformation amount for the work W
necessary for deforming into the target shape can be highly
precisely calculated in a short time period.
[0136] For example, as depicted in FIG. 9E, the first alignment
axis PA1 and the second alignment axis PA2 each having a length
equal to that of each other are aligned relative to each other. The
best fit process of rotating (the reference line CLin in) the
intermediate shape data Fin centering the first alignment axis PA1
to thereby overlapping the reference line CLin on the corresponding
reference line CLt in the target shape data Ft is thereafter
executed. The change of the positional posture of the intermediate
shape data Fin for the best fitting is limited to only the rotation
centering the first alignment axis PA1 as above, and the
intermediate shape data Fin can therefore be highly precisely
overlapped on the target shape data Ft in a short time period.
[0137] According to this method, to best fit the reference line
CLin in the intermediate shape data Fin to the corresponding
reference line CLt in the target shape data Ft whose shapes are
different from each other, the intermediate shape data Fin can be
highly precisely overlapped on the target shape data Ft in a short
time period compared to another best fit process for which the
change of the positional posture of the reference line CLin is not
limited.
[0138] In this embodiment, the intermediate shape data Fin as
depicted in FIG. 7 is acquired by the reference line shape data
producing part 58 of the computing apparatus 18, extracting the
reference line from the 3-D measurement data Fm from the 3-D laser
scanner 14, the shot image Pr from the camera 16, and the shot
image Pr to produce the reference line shape data Fcl, and the
intermediate shape data producing part 60 of the computing
apparatus 18, producing the intermediate shape data Fin from the
3-D measurement data Fm and the reference line shape data Fcl.
These parts function as the intermediate shape data acquiring
part.
[0139] The intermediate shape data of the work W having a large
shape can be produced in a short time period by using the 3-D laser
scanner 14 as a means of acquiring the intermediate shape data.
[0140] In this embodiment, the contour chart is produced based on
the necessary deformation amount for deforming into the target
shape for each of the plural positions on the work having the
intermediate shape. The worker referring to the contour chart can
intuitively learn the information such as the state of the overall
work having the intermediate shape, the position to be
bending-processed from now on, and the bending-processing amount
thereof.
[0141] The present invention has been described with reference to
the above embodiment while the embodiment of the present invention
is not limited to this.
[0142] For example, in the embodiment, because the 3-D measurement
precision of the 3-D laser scanner 14 is low, that is, any
reference line on the work W cannot be detected, the camera 16 is
complementarily used as a means to detect the reference line. When
the 3-D laser scanner 14 can detect the reference line on the work
W, that is, when the reference line appears in the 3-D measurement
data, the camera 16 may not be used. The 3-D laser scanner 14
functions as a means of acquiring the intermediate shape data of
the work including the reference line.
[0143] Concerning the above, the work having the intermediate shape
is shot by the camera from plural directions without using any 3-D
laser scanner, and the intermediate shape data of the work can be
produced based on the plural pieces of shot image data. For
example, the computing apparatus includes the intermediate shape
data producing part that produces the intermediate shape data by
extracting partial shapes of the work from the shot images and
synthesizing the pieces of extracted partial shape data into one.
In this case, not only the partial shapes of the work but also the
shape of the reference line on the work can be extracted from the
shot images by the camera. As a result, the intermediate shape data
including the reference line on its surface can be acquired.
[0144] The deformation processing for the work (the plural bending
processing sessions) is(are) executed by a press processing machine
in the embodiment while the embodiment of the present invention is
not limited to this. For example, the processing may be spinning
processing or the like. The embodiment of the present invention
relates to deformation processing for a work, that varies the shape
of the work without removing any portion thereof, in the broad
sense.
[0145] The plural reference lines are disposed in the grid form in
the target shape data and on the work as depicted in FIG. 3 and
FIG. 5 in the embodiment while the embodiment of the present
invention is not limited to this. The present invention can be
implemented when at least one reference line is present. For any
reference line to reliably be present in any optional processing
scheduled region to be deformation-processed on the work, the
plural reference lines are preferably disposed and are more
preferably disposed in the grid form. The target shape data and the
intermediate shape data are overlapped on each other by alignment
using the reference lines at a position at which no more bending
processing can be executed for the reason such as, for example, a
small thickness, and the deformation amount can thereby be
calculated that is necessary for deforming into the target shape
for each of the other positions on the work. The necessary
deformation amount in the optional processing scheduled region can
highly precisely be calculated as above. The degree of freedom is
improved concerning the manner of the deformation processing for
the work compared to the case where the reference line is disposed
on a portion of the surface of each of the target shape data and
the work.
[0146] In the embodiment, the processing scheduled region of the
work to be deformation-processed next is determined by the worker.
The present invention is however not limited to this. For example,
defining the region whose necessary deformation amount calculated
by the necessary deformation amount calculating part 62 of the
computing apparatus 18 is the maximal as the region to be
deformation-processed next, the deformation processing for the work
can be automated. For example, when the deformation processing for
a region of the work is completed, the intermediate shape data
acquired from the work is overlapped on the target shape data, and
the region including the position on the work whose necessary
deformation amount necessary for deforming into the target shape is
maximal is determined as the next processing region. The computing
apparatus 18 controls the processing machine (such as, for example,
the press processing machine 12) and the controlled processing
machine automatically deformation-processes the determined
processing region. The work can automatically be
deformation-processed into the target shape by repeating the
above.
[0147] An aspect of the present invention is, in the broad sense, a
deformation processing support system calculating the necessary
deformation amount necessary for deformation from an intermediate
shape of a work to a target shape thereof based on the difference
between the intermediate shape and the target shape in deformation
processing for the work, that includes a target shape data
acquiring part that acquires target shape data of the work having a
reference line disposed on its surface, an intermediate shape data
acquiring part that acquires intermediate shape data from the work
having the intermediate shape and having a reference line marked on
its surface, during the deformation processing, and a necessary
deformation amount calculating part that overlaps the target shape
data and the intermediate shape data on each other by aligning the
reference lines relative to each other and that calculates a
necessary deformation amount for each of plural positions on the
work based on the difference between the target shape data and the
intermediate shape data overlapped on each other, and of which, as
the overlapping of the target shape data and the intermediate shape
data on each other, the necessary deformation amount calculating
part sets a first starting point and a first ending point on the
reference line in the intermediate shape data, calculates a
straight-line first alignment axis that connects the first starting
point and the first ending point to each other, sets a second
starting point corresponding to the first starting point on the
reference line in the target shape data, calculates a point on the
reference line in the target shape data, that is distant from the
second starting point by a distance equal to the length of the
first alignment axis, as a second ending point, calculates a
straight-line second alignment axis that connects the second
starting point and the second ending point to each other, overlaps
the intermediate shape data and the target shape data on each other
such that the first alignment axis and the second alignment axis
are overlapped on each other in the state where the first starting
point and the second starting point match with each other, and
relatively rotates the intermediate shape data relative to the
target shape data centering the first alignment axis and the second
alignment axis overlapped on each other.
[0148] Another aspect of the present invention is, in the broad
sense, a deformation processing support method of calculating a
necessary deformation amount necessary for deformation from an
intermediate shape of a work to a target shape thereof based on the
difference between the intermediate shape and the target shape in
deformation processing for the work, that includes the steps of
acquiring target shape data of the work having a reference line
disposed on its surface, marking a reference line on the surface of
the work before the deformation processing is started, acquiring
intermediate shape data from the work having the intermediate shape
and having the reference line marked on its surface, during the
deformation processing, overlapping the target shape data and the
intermediate shape data on each other by aligning the reference
lines relative to each other, and calculating a necessary
deformation amount for each of plural positions on the work having
the intermediate shape based on the difference between the target
shape data and the intermediate shape data overlapped on each
other, and, as the overlapping of the target shape data and the
intermediate shape data on each other, setting a first starting
point and a first ending point on the reference line in the
intermediate shape data, calculating a straight-line first
alignment axis that connects the first starting point and the first
ending point to each other, setting a second starting point
corresponding to the first starting point on the reference line in
the target shape data, calculating a point on the reference line in
the target shape data, that is distant from the second starting
point by a distance equal to the length of the first alignment
axis, as a second ending point, calculating a straight-line second
alignment axis that connects the second starting point and the
second ending point to each other, overlapping the intermediate
shape data and the target shape data on each other such that the
first alignment axis and the second alignment axis are overlapped
on each other in the state where the first starting point and the
second starting point match with each other, and relatively
rotating the intermediate shape data relative to the target shape
data centering the first alignment axis and the second alignment
axis overlapped on each other.
[0149] The embodiment has been described as above as
exemplification of the technique of the present invention. The
accompanying drawings and the detailed description have been
provided therefor. The constituent elements depicted in the
accompanying drawings and described in the detailed description may
therefore include not only the constituent elements essential for
solving the problem but also the constituent elements not essential
for solving the problem to exemplify the technique. The unessential
constituent elements should not readily be acknowledged to be
essential based on the fact that the unessential constituent
elements are depicted in the accompanying drawings and described in
the detailed description.
[0150] The embodiment is to exemplify the technique of the present
invention, and various changes, replacements, additions, omissions,
and the like can therefore be made thereto within the scope of the
appended claims or the scope of the equivalence thereof.
[0151] The entirety of the disclosed content of the specification,
drawings, and the appended claims of Japanese Patent Application
No. 2017-076003 filed on Apr. 6, 2017 is incorporated herein by
reference.
INDUSTRIAL APPLICABILITY
[0152] The present invention is applicable to any deformation
processing of deforming the shape of a work.
* * * * *