JP7206486B2 - Structure manufacturing method - Google Patents

Description

The present invention relates to a structure manufacturing method.

Patent Literature 1 discloses a resin panel configured by sandwiching a core material between a pair of resin sheets.

JP 2014-79901 A

Patent Document 1 describes that a core material is arranged between a pair of resin sheets using a manipulator or the like, and then the core material is pressed against one of the resin sheets and welded.

In such a manufacturing method, it is necessary to weld the core material to a specific position of the resin sheet. The manipulator can convey the core material with high accuracy, but it is not easy to accurately position the core material with respect to the suction head of the manipulator.

SUMMARY OF THE INVENTION The present invention has been made in view of such circumstances, and provides a method of manufacturing a structure that enables easy and highly accurate positioning of a target member.

According to the present invention, the structure manufacturing method includes the tilting step, in which the positioning table is tilted so that the target member placed on the positioning table is slid and locked. A method is provided for positioning the target member by abutting a portion.

In the present invention, the target member is positioned by sliding the target member placed on the positioning table and bringing it into contact with the locking portion. According to such a method, the target member can be positioned easily and with high accuracy.

Various embodiments of the present invention are illustrated below.
Preferably, in the method described above, the positioning table is configured to be rotatable about first and second rotation axes, the first rotation axis and the second rotation axis are orthogonal to each other, and the The locking portion includes a first locking portion and a second locking portion, the tilting step includes a first rotating shaft rotating step and a second rotating shaft rotating step, and the first rotating shaft rotating step is provided. In the moving step, the target member is slid to come into contact with the first locking portion by rotating the positioning base about the first rotating shaft, and in the second rotating shaft rotating step, the second In this method, the object member is slid to come into contact with the second engaging portion by rotating the positioning base about two rotation axes.
Preferably, the method as described above, wherein the target member comprises a pair of substrates engaged by an elongate reinforcing member.
Preferably, the method described above includes a substrate position correcting step after the tilting step, wherein the substrate position correcting step adjusts the positional deviation between the pair of substrates along the longitudinal direction of the reinforcing member. A way to fix it.
Preferably, the method described above includes a reinforcing member position correcting step after the tilting step, wherein the reinforcing member correcting step corrects a positional deviation of the reinforcing member with respect to the pair of bases. be.
Preferably, the method as described above comprises, before said tilting step, a removing step, wherein said object located at the top of a target member stack formed by stacking a plurality of said target members. In this method, the member is taken out and moved onto the positioning table.
Preferably, the above-described method further comprises a holding step after the tilting step, wherein the holding step holds and moves the target member with a manipulator while the target member is positioned. .
Preferably, the method described above includes a heating step before the tilting step, wherein the heating step heats the target member.
Preferably, the method as described above, wherein the step of warming is performed by warming the target member in the stack of target members.

1A is a perspective view of a resin panel 1, and FIG. 1B is a perspective view of a core material 3. FIG. 2A is an exploded perspective view of the core material 3, FIG. 2B is an enlarged view of a region B in FIG. 2A, and FIG. 2C is an end view of the reinforcing member 3c. 2 is a plan view of manufacturing system 20. FIG. 4 is an enlarged view of the vicinity of the member supply line 7 of the manufacturing system 20; FIG. 5A and 5B are sectional views taken along lines AA and BB in FIG. 4, respectively. FIG. 5 is a diagram corresponding to FIG. 4 for explaining the operation of the core material carrier 22 and the skin material carrier 23; 7A is a perspective view of the head 24 of the manipulator 5, and FIGS. 7B-7C are enlarged views of area B and area C, respectively, in FIG. 7A. 4 is a perspective view of a state in which the core material 3 is adsorbed to the head 24; FIG. 9A shows a state in which the positioning table 8a of the positioning device 8 is horizontal, and FIG. 9B shows a state in which the positioning table 8a is inclined. 10A is a perspective view for explaining the substrate position correcting step, and FIG. 10B is an enlarged view of region B in FIG. 10A. FIG. 11A is a perspective view for explaining the reinforcing member position correcting step, and FIGS. 11B to 11C are enlarged views of area B and area C in FIG. 11A, respectively. 12A is a perspective view of the insertion device 9, and FIG. 12B is an enlarged view of area B in FIG. 12A. 4 is a perspective view of a state in which the core material 3 is adsorbed to the insertion device 9. FIG. FIG. 10 is a perspective view for explaining a skin material positioning step; 15A is a perspective view of the head 24 holding the skin material 4, and FIG. 15B is an enlarged view of the region B in FIG. 15A. 16A is a perspective view for explaining the process of transferring the skin material 4 from the head 24 to the inserting device 9, and FIG. 16B is an enlarged view of area B in FIG. 16A. 17A to 17E are front views for explaining the process of transferring the skin material 4 from the male holding portion 24d to the female holding portion 9c. 2 is a front view showing the configuration of the molding machine 10 (molds 71 and 72 and members in the vicinity thereof are cross-sectional views). FIG. 19A is a perspective view of the mold 71, and FIG. 19B is an exploded perspective view of the mold 71. FIG. FIG. 19 is a diagram corresponding to FIG. 18 for explaining the molding process; 4 is a front view of a molded body 26; FIG. 22A and 22B are front views showing the operation of the movable portion 71g when the die 71 performs the first cutting step. FIG. 4 is a perspective view showing a state in which the clamping device 12 clamps the molded body 26 with the molds 71 and 72 closed. 24A shows a state in which the molds 71 and 72 are removed from FIG. 23, and FIG. 24B is an enlarged view of area B in FIG. 24A. 25A is a perspective view of the holding device 13, and FIG. 25B is an enlarged view of area B in FIG. 25A. 4 is a perspective view of the holding device 13 with the holding mechanism 13e in a standby state; FIG. 27A and 27B are perspective views for explaining the process of holding the compact 26 by the holding device 13. FIG. FIG. 28A is a perspective view of a state in which holding of the compact 26 by the holding device 13 is completed, and FIG. 28B shows a state in which the holding table 13b is tilted to remove the upper burrs 26bu. FIG. 3 is a perspective view of the holding device 13 holding the molded body 26 with the holding table 13b horizontal. 4 is a perspective view of the head 27 of the manipulator 6; FIG. FIG. 31A is a perspective view of the holding device 13 holding the compact 26 for explaining the second cutting step, and FIG. 31B is an enlarged view of the region B in FIG. 31A. FIG. 31B is a perspective view of the state of FIG. 31A with the molded body main body 26a removed; FIG. 33A is a perspective view of the holding table 13b in a folded state, and FIG. 34B is an enlarged view of area B in FIG. 34A. Illustration of the holding mechanism 13e is omitted. FIG. 34A is an end view of the holding table 13b in a folded state. FIG. 34B is an end view of a state in which the connecting member 13b2 and the arm 13b3 are asymmetrically rotated. FIG. 34C is an end view of the state where the lower burr plate 13g and the upper burr plate 13h are attached to the arm 13b3. FIG. 34D is an end view of the holding table 13b in a burr discharging state. Illustration of the holding mechanism 13e is omitted. 4 is a perspective view of the holding device 13 and the burr inserting device 17 for explaining the discharging process; FIG. Illustration of the holding mechanism 13e is omitted. FIG. 4 is a perspective view of the burr throwing device 17 for explaining the rising process; 37A is a perspective view of the inspection device 14, the press device 15, and the stacking device 16 arranged along the conveyor 28. FIG. FIG. 37B shows a state in which the compact main body 26a is removed from FIG. 37A. FIG. 37C is a front view of FIG. 37A. FIG. 38A is a perspective view of the inspection device 14 and the conveyor 28 as seen from the back side. FIG. 38B is a right side view of FIG. 38A. FIG. 38C is a right side view of the weighing platform 14a lifted from FIG. 38B. FIG. 39A is a perspective view of a state in which the feeder 29 is used to convey the molded body 26a toward the press device 15. FIG. 39B is a front view of a state in which the molded body main body 26a is arranged inside the press device 15. FIG. FIG. 40A is a perspective view of the compact body 26a placed in the stacking device 16. FIG. FIG. 40B is a right side view of FIG. 40A. 41A to 41C are right side views showing the operation of the stacking device 16 when stacking the compact bodies 26a.

Embodiments of the present invention will be described below. Various features shown in the embodiments shown below can be combined with each other. In addition, the invention is established independently for each characteristic item.

1. Resin panel 1
As shown in FIG. 1, a resin panel 1 (an example of a “structure”) according to one embodiment of the present invention is a panel covered with a substantially rectangular resin molding 2 in plan view.

As shown in FIGS. 1 and 2, the resin panel 1 includes a hollow resin molded body 2 and a core material 3 , and the core material 3 is arranged inside the resin molded body 2 . A skin material 4 is attached to one side of the resin molding 2 so as to extend to the parting line PL. The skin material 4 is, for example, a non-woven fabric, and is integrally molded with the resin molding 2 during molding.

Both surfaces of the core material 3 are in close contact with the resin molding 2 . The core material 3 is composed of bases 3a and 3b and a reinforcing member 3c connecting them. The reinforcing member 3c is an elongated member with a constant cross-sectional shape. The substrates 3a and 3b are made of foam, for example. The reinforcing member 3c has a substantially H shape and is composed of an upper wall 3c1, a lower wall 3c2, and a column portion 3c3 connecting them. Both ends of the upper wall 3c1 in the width direction are provided with projections 3c11 projecting toward the lower wall 3c2. Both ends of the lower wall 3c2 in the width direction are provided with projections 3c21 projecting toward the upper wall 3c1. By engaging the protrusions 3c11 and 3c21 with the bases 3a and 3b, the bases 3a and 3b and the reinforcing member 3c are integrated. At the ends of the substrates 3a and 3b, concave portions 3a1 and 3b1 are provided which are one step lower. The upper and lower surfaces of are substantially flush with each other.

2. Manufacturing system 20 for resin panel 1
The resin panel 1 can be manufactured using the manufacturing system 20 shown in FIG. In the manufacturing system 20, only the replenishment of the core material 3 and the skin material 4 and the taking out of the compact body 26a (see FIG. 41) placed on the stacking device 16 are performed manually, and the other processes are performed automatically. is done in Therefore, the manufacturing system 20 can be operated by a small number (for example, one) of operators 21 . Moreover, in the manufacturing system 20, the manufacturing line is arranged in a substantially U shape, and can be installed in a relatively small space.

As shown in FIGS. 3 to 5, the manufacturing system 20 includes first and second manipulators 5 and 6, a member supply line 7, a positioning device 8, an inserting device 9, a molding machine 10, a clamping device 12, , a holding device 13 , a conveyor 28 , an inspection device 14 , a press device 15 , a stacking device 16 , a burr charging device 17 and a crusher 18 . The manipulators 5 and 6 are configured, for example, by attaching a head having required functional members to a robot arm having six or more axes. The first manipulator 5 is configured to be movable on the carriage 5a. The second manipulator 6 is fixed on the mounting table 6a. The holding device 13 is fixed on a carrier 13d that is movable along the carrier line 13a.

In the following description, reference will be made to the X-axis and Y-axis defined as shown in FIG. 3 as appropriate. The X-axis is the conveying direction on the conveying line 13a. In the conveying line 13a, the direction from the clamping device 12 to the burr inserting device 17 is defined as "+X direction", and the opposite direction is defined as "-X direction". The Y-axis is an axis perpendicular to the X-axis on the horizontal plane. The direction from the positioning device 8 to the molding machine 10 is defined as "+Y direction", and the opposite direction is defined as "-Y direction".

Here, the general flow of the members will be described. First, the core material 3 and the skin material 4 are conveyed along the member supply line 7 from the operator 21 toward the positioning device 8 in the -X direction. Next, the manipulator 5 and the inserting device 9 convey the core material 3 and the skin material 4 from the positioning device 8 toward the molding machine 10 in the +Y direction, where they are molded by the molding machine 10 to form the molding 26 shown in FIG. be done. The compact 26 is conveyed in the -Y direction by the clamping device 12 and held by the holding device 13 . In the holding device 13, the molded body 26 is separated into a molded body body 26a and large burrs 26b. The large burr 26 b is conveyed in the +X direction by the holding device 13 and thrown into the burr throwing device 17 . On the other hand, the molded body 26a is conveyed by the manipulator 6 toward the conveyor 28 in the -Y direction, and then conveyed on the conveyor 28 in the +X direction. In this manner, the compact body 26a and the large burrs 26b are conveyed in the same direction. Also, the core material 3 and the skin material 4 are conveyed in the direction opposite to the molded body body 26a and the large burr 26b. Such a configuration makes it possible to configure the manufacturing system 20 in a narrow space.

3. Method for Manufacturing Resin Panel 1 Using the manufacturing system 20, the resin panel 1 can be manufactured by carrying out the following manufacturing steps. The method for manufacturing the resin panel 1 of the present embodiment includes a member replenishment process, a core material delivery process, a skin material delivery process, a molding process, a molding removal process, a holding process, a separation process, and a burr treatment. and a main processing step. The holding process, the separating process, and the deburring process are performed on the same straight line along the transfer line 13a. Each step will be described in detail below.

2-1. Member Replenishing Step In the member replenishing step, the core material 3 and the skin material 4 are replenished using the member supply line 7 . As shown in FIGS. 4 and 5, the manufacturing system 20 is provided with two equivalent member supply lines 7. Each member supply line 7 has a core material carrier 22 and a skin material carrier 23. are spaced apart in the vertical direction. The core material carrier 22 and the skin material carrier 23 are each configured to be movable along the X-axis by, for example, a screw feed mechanism.

A large number of core materials 3 are stacked and placed on the core material carrier 22 . When the core material 3 is present on the core material carrier 22, it is arranged at the standby position shown in FIG. As will be described later, the core material 3 on the core material carrier 22 is taken out in order from the top by the manipulator 5 . When it is detected that the core material 3 has run out on the core material carrier 22, the core material carrier 22 moves to the replenishment position shown in FIG. When the operator 21 replenishes the core material 3 at the replenishment position, the core material carrier 22 returns to the standby position.

A large number of skin materials 4 are stacked on the skin material carrier 23 . When the skin material 4 is present on the skin material carrier 23, it is arranged at the standby position shown in FIG. As will be described later, the skin material 4 on the skin material carrier 23 is taken out in order from the top by the manipulator 5 . When it is detected that there is no skin material 4 on the skin material conveying table 23, the skin material conveying table 23 moves to the replenishment position shown in FIG. When the operator 21 replenishes the skin material 4 at the replenishment position, the skin material carrier 23 returns to the standby position.

The core material carrier 22 and the skin material carrier 23 are provided with locking portions such as pillars, and the core material 3 and the skin material 4 are positioned by pressing the core material 3 and the skin material 4 against these locking portions. You may Although the core material 3 and the skin material 4 are positioned to some extent by this method, since the core material 3 and the skin material 4 are overlapped, positional deviation is likely to occur, and the positioning accuracy of the core material 3 and the skin material 4 is low. A positioning process, which will be described later, is required.

The skin material carrier 23 moves under the core material carrier 22 . As shown in FIGS. 4 and 5B, the standby position of the skin material carrier 23 is below the positioning table 8 a of the positioning device 8 . Further, in a plan view, the carriage 5a of the manipulator 5 is arranged between the standby position of the skin material carriage 23 and the standby position of the core material carriage 22 . With such a configuration, it is possible to replenish the core material 3 and the skin material 4 and supply them to the manipulator 5 in a small space. In addition, since two member supply lines 7 are provided, the supply of members to the manipulator 5 does not stop even during replenishment of members on one line.

2-2. Core Material Delivery Process In the core material delivery process, the core material 3 on the core material carrier 22 is delivered to the insertion device 9 . The core material delivery process includes a core material take-out process, a core material positioning process, a core material holding process, and a core material delivery completion process.

<Core material removal process>
In the core material take-out step (an example of a “take-out step”), a core material stack (an example of a “target member stack”) configured by stacking a plurality of core materials 3 (an example of a “target member”) The positioned core material 3 is taken out and moved onto the positioning table 8 a of the positioning device 8 . This step can be performed using the manipulator 5 .

The manipulator 5 has a head 24 shown in FIG. 7 at its tip. The head 24 includes a base 24a, a suction pad 24b, a needle gripper 24c, a male holding portion 24d, and a reinforcing member positioning mechanism 24e. Each member is held by a base 24a. Details of each member will be described later as appropriate.

The suction pad 24b is used to hold the core material 3 by suction. The suction pad 24b is configured such that the amount of protrusion from the base 24a can be adjusted. The number of suction pads 24b required to hold the core material 3 may be provided, and eight suction pads 24b are provided in this embodiment.

The suction pad 24b has a bellows shape, and is configured to shorten as the force applied in the direction perpendicular to the suction surface 24b1 of the suction pad 24b increases. The eight suction pads 24b are adhered to different regions of the core material 3, and there may be height differences between these regions. In such a case, with the conventional suction pad, it was difficult to suck the low-lying region. Therefore, when the head 24 is pressed against the core material 3, the suction pads 24b are appropriately shortened according to the height of the area where the suction pads 24b are sucked, so that the core material 3 can be reliably held by all the suction pads 24b. can be adsorbed.

The manipulator 5 moves the head 24 toward the core material carrier 22 in a state in which the suction pad 24b protrudes more than the other members so that members other than the suction pad 24b do not interfere with the core material 3. , as shown in FIG. 8, the core material 3 is sucked and held by the suction pad 24b.

By the way, the core material 3 is not accurately positioned on the core material carrier 22 (that is, there is variation in the position of the core material 3 on the core material carrier 22). It is taught in advance that the manipulator 5 sucks the core material 3 placed at the standby position of the core material carrier 22 . For this reason, the suction pad 24b sucks the core material 3 without recognizing the exact position of the core material 3, so the position at which the suction pad 24b sucks the core material 3 varies slightly each time. Therefore, if the core material 3 is passed to the inserting device 9 as it is, the position of the core material 3 in the inserting device 9 also varies, leading to variations in product quality. Therefore, in the present embodiment, the following core material positioning process is performed.

<Core material positioning process>
In the core material positioning process, the manipulator 5 and the positioning device 8 are used to position the core material 3 . The core material positioning process includes a tilting process, a base body position correcting process, and a reinforcing member position correcting process. The positioning device 8 is provided with a sensor (not shown), and can detect whether or not the core material 3 or the skin material 4 exists on the positioning table 8a. , the core material extraction process can be performed again, or a warning can be issued.

- Tilting process The tilting process can be performed using the positioning device 8 . As shown in FIG. 9A, the positioning device 8 includes a positioning base 8a, a locking portion 8b, and a rotating mechanism 8c. As shown in FIG. 4, the rotating mechanism 8c is fixed on the pedestal 8d. The rotating mechanism 8c includes a base 8c1, a first rotating member 8c2, and a second rotating member 8c3. The rotating mechanism 8c includes first and second rotating mechanisms. The first rotating member 8c2 rotates about a first rotating shaft 8c4 parallel to the Y-axis with respect to the base 8c1 (first rotating mechanism). The second rotating member 8c3 rotates relative to the first rotating member 8c2 about a second rotating shaft 8c5 orthogonal to the first rotating shaft 8c4 (first rotating mechanism). The rotating mechanism 8c is configured by, for example, a biaxial robot. The positioning table 8a is connected to the second rotating member 8c3. Therefore, the positioning table 8a is tilted by being driven by the rotating mechanism 8c. The locking portion 8b includes a first locking portion 8b1 and a second locking portion 8b2. The positioning device 8 having such a configuration can also be used for positioning a member (for example, the skin material 4) whose characteristics such as thickness and rigidity are significantly different from those of the core material 3. FIG.

In the tilting step, as shown in FIG. 9A, the core material 3 is placed on the positioning table 8a, and as shown in FIG. The core member 3 is positioned by sliding the core member 3 placed on the positioning table 8a and bringing it into contact with the engaging portion 8b. At this point, the core material 3 does not need to be positioned with respect to the positioning table 8a, so the core material 3 is placed on the positioning table 8a by dropping the core material 3 from several millimeters above the positioning table 8a. may

More specifically, in the first rotating shaft rotating step, the positioning table 8a is rotated around the first rotating shaft 8c4 to slide the core material 3 and bring it into contact with the first engaging portion 8b1, In the second rotating shaft rotating step, the positioning table 8a is rotated around the second rotating shaft 8c5 to slide the core material 3 and bring it into contact with the second engaging portion 8b2. The first and second rotating shaft rotating steps may be performed simultaneously, or one of them may be performed first.

Substrate Position Correcting Step Incidentally, the core material 3 is composed of the substrates 3a and 3b and the reinforcing member 3c connecting the substrates 3a and 3b. The positional relationship between 3a, 3b and reinforcing member 3c may shift along the longitudinal direction of reinforcing member 3c. In some cases, such a deviation cannot be eliminated simply by tilting the positioning table 8a.

In the state of FIG. 10, the reinforcing member 3c and the base body 3a are displaced in the direction away from the first locking portion 8b1. In this state, the base 3b is in contact with the first engaging portion 8b1 and positioned accurately, but the reinforcing member 3c and the base 3a are not positioned. Therefore, it is necessary to correct the positions of the reinforcing member 3c and the base 3a.

Therefore, in the base body position correcting step, as shown in FIG. 10, a force is applied to the base body 3a in the direction of the arrow L to press the base body 3a against the first engaging portion 8b1, so that the reinforcement member 3c is moved along the longitudinal direction. Also, the positional deviation of the substrate 3a is corrected.

Specifically, this step can be performed by pressing the base body 3a against the first engaging portion 8b1 with the tubular portion 24d2 of the male holding portion 24d shown in FIGS. 7A and 7B. 17, the cylindrical portion 24d2 is originally a member used for pushing the skin material 4 when moving the skin material 4 from the male projection 24d1 to the female projection 9c1. A member other than 24d2 may be used to press base body 3a against first engaging portion 8b1.

In some cases, the base body 3a abuts on the first engaging portion 8b1 and the base body 3b is displaced so as to separate from the first engaging portion 8b1. , it is possible to correct the positional displacement of the base 3b along the longitudinal direction of the reinforcing member 3c.

In this step, the displacement between the bases 3a and 3b along the longitudinal direction of the reinforcing member 3c is corrected by the above method.

Reinforcing Member Position Correcting Step In the reinforcing member correcting step, positional deviation of the reinforcing member 3c with respect to the bases 3a and 3b is corrected. This step can be performed using a reinforcing member positioning mechanism 24e shown in FIGS. 7A and 7C.

The head 24 is provided with a pair of reinforcing member positioning mechanisms 24e. Each reinforcing member positioning mechanism 24e includes a first base 24e1, a first rod 24e2, a second base 24e3, and a second rod 24e4. The first base 24 e 1 is fixed to the base 24 a of the head 24 . The first rod 24e2 extends along the in-plane direction of the member mounting surface 24a1 of the base 24a of the head 24, and the amount of protrusion from the first base 24e1 can be adjusted. The second base 24e3 is fixed to the first rod 24e2. The second rod 24e4 extends in a direction perpendicular to the member mounting surface 24a1, and the amount of protrusion from the second base 24e3 can be adjusted.

When correcting the misalignment of the reinforcement member 3c, as shown in FIG. By moving the two rods 24e4 in the directions of arrows L1 and L2 to reduce the distance between the pair of second rods 24e4, the reinforcing member 3c is sandwiched between the pair of second rods 24e4. As a result, the reinforcing member 3c is arranged at an appropriate position, so that the displacement of the reinforcing member 3c with respect to the bases 3a and 3b is corrected.

<Core material holding process>
In the core material holding step (an example of the “holding step”), the manipulator 5 holds and moves the core material 3 in a positioned state. The holding and moving of the core material 3 by the manipulator 5 can be performed in the same manner as in the core material extraction step.

<Core material delivery completion process>
In the core material delivery completion process, the manipulator 5 delivers the core material 3 to the insertion device 9 . This completes delivery of the core material.

The insertion device 9 is configured to be movable by a driving mechanism (not shown). As shown in FIG. 12, the insertion device 9 includes a base 9a, a suction pad 9b, and a female holding portion 9c. Each member is held by a base 9a. Details of each member will be described later as appropriate.

The suction pad 9b is used to hold the core material 3 by suction. The suction pad 9 b is provided at a position facing the suction pad 24 b of the head 24 .

With the manipulator 5 bringing the core material 3 into contact with the suction pad 9b, suction by the suction pad 9b is started and suction by the suction pad 24b is stopped. It can be handed over to the insertion device 9 .

2-3. Skin Material Delivery Process In the skin material delivery process, the skin material 4 on the skin material carrier 23 is delivered to the insertion device 9 . The skin material delivery process includes a skin material take-out process, a skin material positioning process, a skin material holding process, and a skin material delivery completion process.

<Skin material removal process>
In the skin material removing step, the skin material 4 positioned at the top of the skin material stack formed by stacking a plurality of skin materials 4 (an example of a "target member") is taken out and placed on the positioning table 8a of the positioning device 8. move to This step can be performed using the manipulator 5 .

As shown in FIG. 4, when the positioning table 8a is horizontal, the positioning table 8a overlaps the skin material conveying table 23 in plan view. may interfere with the positioning table 8a. Therefore, before holding the skin material 4 by the manipulator 5, the positioning table 8a is rotated so that the positioning table 8a does not overlap the skin material conveying table 23 in plan view. In one example, the positioning table 8a can be rotated so that the positioning table 8a is perpendicular to the upholstery carrier 23 .

A needle gripper 24c provided on the head 24 of the manipulator 5 is configured to hold a plurality of needles by obliquely piercing a breathable member such as a nonwoven fabric. In this embodiment, the needle gripper 24c is used to hold the skin material 4. As shown in FIG. The needle gripper 24c is configured such that the amount of protrusion from the base 24a can be adjusted. Needle grippers 24c may be provided in a number required to hold the upholstery material 4, and four needle grippers 24c are provided in this embodiment.

The manipulator 5 moves the head 24 toward the skin material carrier 23 in a state in which the needle gripper 24c protrudes more than other members so that members other than the needle gripper 24c do not interfere with the core material 3. , the needle of the needle gripper 24c is pierced into the skin material 4 and held.

By the way, like the core material 3 , the skin material 4 is not accurately positioned on the skin material carrier 23 . For this reason, in this embodiment, the skin material positioning process described below is performed.

<Surface Material Positioning Process>
As shown in FIG. 14, in the skin material positioning process, the skin material 4 is positioned by performing the same operation as the tilting process of the core material positioning process.

By the way, the skin material 4 is usually manufactured by cutting a long raw material unwound from a raw roll. For this reason, the edge of the skin material 4 may curl due to the curl of the raw fabric roll being reflected in the skin material 4 . Such a phenomenon tends to occur during cold seasons (for example, when the room temperature is 20° C. or lower (especially 15° C. or lower)). If the edge of the skin material 4 is curled, the skin material 4 may not be properly positioned in the tilting process for positioning the skin material.

Such curling can be alleviated by warming the skin material 4 to soften it. Therefore, in the present embodiment, a heating step for heating the skin material is performed before the tilting step. The heating may be performed so that the curling of the upholstery material 4 is relaxed to the extent that the tilting process can be performed appropriately. The heating step can be omitted if unnecessary.

Moreover, although the entire skin material 4 may be heated, it is sufficient if the side contacting the engaging portion 8b shown in FIG. 14 is not curled. you can go In addition, since the original fabric roll does not curl in the longitudinal direction, the sides of the skin material 4 along the longitudinal direction are less likely to curl. Therefore, among the sides of the skin material 4, the sides other than the sides along the longitudinal direction of the raw fabric roll may be heated. In the present embodiment, the long sides of the skin material 4 (sides contacting the second locking portions 8b2) match the longitudinal direction of the original fabric roll, so the short sides of the skin material 4 (contacting the first locking portions 8b1) contact side) may be heated. By heating a specific region, equipment and implementation costs for the heating process can be reduced.

In this embodiment, as shown in FIG. 4, a heater (eg, an infrared heater) 30 is provided at a position adjacent to the standby position of the skin material carrier 23, and the skin material 4 is heated using this heater 30. ing. Therefore, the heating is carried out by heating the skin material 4 in the state of the skin material stack. This makes it possible to heat the skin material 4 more efficiently than heating the skin material 4 individually.

The heater 30 has an elongated shape and is provided along the short side of the skin material 4 . Therefore, the short sides of the skin material 4 are efficiently heated, and the curling of the short sides of the skin material 4 is alleviated.

Warming may be done in another way. For example, the skin material 4 may be heated by heating the skin material transport base 23 using a heater incorporated in the skin material transport base 23 . Alternatively, an infrared heater may be arranged above the positioning table 8a, and the skin material 4 may be heated while the skin material 4 is placed on the positioning table 8a.

<Skin Material Holding Process>
In the covering material holding process, the covering material 4 is held and moved by the manipulator 5 in a state where the covering material 4 is positioned. This step can be performed using the manipulator 5 .

As shown in FIG. 7B, the male holding portion 24d provided on the head 24 of the manipulator 5 includes a male projection 24d1, a cylindrical portion 24d2, and a base 24d3. The male protrusion 24d1 is configured such that the amount of protrusion from the base 24d3 can be adjusted. The male projection 24d1 has a shaft portion 24d11 and an enlarged diameter portion 24d12, and the enlarged diameter portion 24d12 is tapered toward its tip. As shown in FIG. 15, by inserting the male protrusion 24d1 into the skin material 4 and engaging the skin material 4 with the enlarged diameter portion 24d12, the skin material 4 can be held by the male holding portion 24d. Become. The tubular portion 24d2 is configured such that the amount of protrusion from the base 24d3 can be adjusted. The male projection 24d1 is arranged inside the tubular portion 24d2 and is movable relative to the tubular portion 24d2.

The male holding portion 24d is arranged at a position slightly outside the outer periphery of the core material 3 so as not to interfere with the core material 3. As shown in FIG. The number of male-type holding portions 24d required to hold the skin material 4 may be provided, and in this embodiment, four male-type holding portions 24d are provided.

The skin material 4 is provided with a slit-like opening at a position facing the male projection 24d1 so that the male projection 24d1 can be easily inserted into the skin material 4. As shown in FIG.

The manipulator 5 moves the head 24 toward the positioning table 8a, pierces the needle of the needle gripper 24c into the skin material 4, and inserts the male projection 24d1 into the skin material 4 as shown in FIG. Material 4 is held. The positioning table 8a is provided with a recess at a position facing the male protrusion 24d1 in order to avoid interference between the male protrusion 24d1 and the positioning table 8a.

<Surface material delivery completion process>
In the skin material delivery completion process, the manipulator 5 delivers the skin material 4 to the insertion device 9 . Thus, delivery of the skin material 4 is completed.

As shown in FIG. 12B, the female holding portion 9c provided in the insertion device 9 includes a female projection 9c1, a tubular portion 9c2, and a base 9c3. The female protrusion 9c1 is configured such that the amount of protrusion from the base 9c3 can be adjusted. The female projection 9c1 has a shaft portion 9c11 and an enlarged diameter portion 9c12, and the enlarged diameter portion 9c12 is provided with a recess 9c13 at the tip thereof, which can be engaged with the tip of the male projection 24d1. The concave portion 9c13 preferably has a complementary shape to the tip of the male projection 24d1.

As shown in FIG. 17E, by inserting the female projection 9c1 into the skin material 4 and engaging the skin material 4 with the expanded diameter portion 9c12, the skin material 4 can be held by the female holding portion 9c. Become. The cylindrical portion 9c2 is configured such that the amount of protrusion from the base 9c3 can be adjusted. The female projection 9c1 is arranged inside the cylindrical portion 9c2 and is movable relative to the cylindrical portion 9c2. The female holding portion 9c is provided at a position facing the male holding portion 24d.

Specifically, delivery of the skin material 4 is performed by the following method.

First, as shown in FIGS. 16 and 17A, the male projection 24d1 is opposed to the female projection 9c1 while the skin material 4 is held by the male projection 24d1.

Next, as shown in FIG. 17B, the tip of the male projection 24d1 is engaged with the recess 9c13 of the female projection 9c1. Thereby, the male projection 24d1 and the female projection 9c1 are positioned with high accuracy. In FIG. 17B, the amount of protrusion of the female protrusion 9c1 is increased, but the engagement may be performed by increasing the amount of protrusion of the male protrusion 24d1.

Next, as shown in FIG. 17C, the skin material 4 is moved to the shaft portion 9c11 by pushing the skin material 4 with the end surface of the cylindrical portion 24d2. In FIG. 17C, by increasing the amount of projection of the cylindrical portion 24d2, the end face of the cylindrical portion 24d2 presses the skin material 4. However, the amount of projection of the male projection 24d1 is decreased and the amount of projection of the female projection 9c1 is increased. By doing so, the upholstery material 4 may be pushed by the end surface of the tubular portion 24d2.

Next, as shown in FIG. 17D, the cylindrical portion 24d2 is separated from the upholstery material 4. Then, as shown in FIG.

Next, as shown in FIG. 17E, the female projection 9c1 is separated from the male projection 24d1. Thus, delivery of the skin material 4 is completed.

A sensor 25 is provided for confirming that the upholstery material 4 has been delivered. As indicated by an arrow S, the sensor 25 irradiates light to the portion where the female projection 9c1 is inserted through the skin material 4, and based on the reflected light, whether or not the female projection 9c1 is inserted through the skin material 4 is determined. to detect

2-4. Molding Process As shown in FIGS. 18 to 22, in the molding process, a molding machine 10 and an inserting device 9 are used to form a molded body 26 shown in FIG. As shown in FIG. 18 , the molding machine 10 includes a pair of sheet forming devices 64 , first and second molds 71 and 72 , and a lower burr clamping device 78 .

<Molded body 26>
As shown in FIG. 21, the molded body 26 is constructed by connecting a molded body body 26a and a large burr 26b (an example of a "burr") via a cutting line 26c provided so as to surround the molded body body 26a. ing. Therefore, by cutting the molded body 26 along the cutting line 26c along the entire circumference of the molded body 26a, the molded body 26 can be separated into the molded body 26a and the large burrs 26b.

The cutting line 26c includes a left line 26cl, a right line 26cr, an upper line 26cu and a lower line 26cb. In FIG. 21, the left line 26cl and the right line 26cr are indicated by thick lines. The left line 26cl, the right line 26cr, the upper line 26cu, and the lower line 26cb are respectively on the left side of the molded body 26a when the molded body 26 is viewed from the mold closing direction (arrow C2) of the mold 72 shown in FIG. , right, top, and bottom.

In the present embodiment, a first cutting step is performed in which the molded body 26 is cut along the right line 26cr and the left line 26cl by the molds 71 and 72, and after the molded body 26 is removed from the molds 71 and 72, the cutting line 26c (that is, the upper line 26cu and the lower line 26cb) are cut along the second cutting step.

The first cutting step can be performed in a shorter time than the second cutting step. , the time required for the cutting process can be shortened.

The molded body main body 26a is configured by connecting a molded product 26d (corresponding to the resin panel 1) and a small burr 26e via a parting line 26f. Therefore, by cutting the molded product body 26a along the parting line 26f over the entire circumference of the molded product 26d, the molded product 26d and the small burrs 26e can be separated.

The parting line 26f includes a left line 26fl, a right line 26fr, an upper line 26fu, and a lower line 26fb. The left line 26fl, the right line 26fr, the upper line 26fu, and the lower line 26fb are on the left side of the molded body 26a when the molded body 26 is viewed from the mold closing direction (arrow C2) of the mold 72 shown in FIG. , right, top, and bottom.

Left line 26cl and right line 26cr of cutting line 26c include left line 26fl and right line 26fr of parting line 26f, respectively. A lower line 26cb of the cutting line 26c overlaps a lower line 26fb of the parting line 26f.

On the other hand, the upper line 26cu of the cutting line 26c is provided at a position above and adjacent to the upper line 26fu (an example of the "adjacent line") of the parting line 26f. Therefore, the molded product 26d and the small flash 26e are connected via the upper line 26fu.

Since the upper line 26fu of the parting line 26f is nonlinear, it takes time to cut the compact 26 along the upper line 26fu using a cutter. Therefore, in the present embodiment, a linear upper line 26cu is provided at a position adjacent to the upper side of the upper line 26fu, and the compact 26 is cut along the upper line 26cu in the second cutting step. This shortens the time required for the second cutting step.

In order to obtain the molded product 26d, it is necessary to perform a third cutting step of cutting the molded body main body 26a along the upper line 26fu. However, the third cutting step can be performed after moving the compact body 26a from the holding device 13 to another location. The time taken by the second cutting step on the holding device 13 is therefore directly related to the cycle time. In other words, the processing on the holding device 13 is the bottleneck of the manufacturing cycle, and shortening the time required for this processing leads to shortening the cycle time. Therefore, by shortening the time required for the second cutting process and performing the third cutting process at a place other than the holding device 13, the cycle time can be shortened.

The lower line 26cb of the cutting line 26c may be provided below the lower line 26fb of the parting line 26f. Cutting the compact 26 along the parting line 26f must be done slowly and carefully so as not to damage the compact main body 26a. Cutting along the lower line 26cb in the cutting process can be speeded up.

<Structure of Sheet Forming Device 64>
As shown in FIG. 18, the sheet forming device 64 includes a hopper 62, an extruder 63, an accumulator 67, and a T-die 68. The extruder 63 and the accumulator 67 are connected via a connecting pipe 75 . The accumulator 67 and the T-die 68 are connected via a connecting pipe 77 . Each configuration will be described in detail below.

・Hopper 62, extruder 63
The hopper 62 is used to charge the raw material resin 61 into the cylinder 63 a of the extruder 63 . Although the form of the raw material resin 61 is not particularly limited, it is usually in the form of pellets. The raw material resin is, for example, a thermoplastic resin such as polyolefin, and examples of polyolefin include low density polyethylene, linear low density polyethylene, high density polyethylene, polypropylene, ethylene-propylene copolymers and mixtures thereof. The raw material resin 61 may include a recycled raw material produced by pulverizing the large burrs 26 b with the pulverizer 18 . The raw material resin 61 is fed from the hopper 62 into the cylinder 63a, and then heated in the cylinder 63a to be melted into a molten resin. Further, it is conveyed toward the tip of the cylinder 63a by the rotation of the screw arranged in the cylinder 63a. The screw is arranged in the cylinder 63a, and conveys the molten resin while kneading it by its rotation. A gear device is provided at the proximal end of the screw, and the screw is rotationally driven by the gear device.

・Accumulator 67, T-die 68
The raw material resin is extruded from the resin extrusion port of the cylinder 63 a and injected into the accumulator 67 through the connecting pipe 75 . The accumulator 67 has a cylinder 67a and a piston 67b slidable inside the cylinder 67a, and the molten resin 61a can be stored in the cylinder 67a. By moving the piston 67b after a predetermined amount of the molten resin 61a is stored in the cylinder 67a, the molten resin 61a is extruded through the connecting pipe 77 from a slit provided in the T die 68 and is allowed to hang down to be in a molten state. First and second resin sheets 73a and 73b are formed.

<Structures of molds 71, 72 and lower burr clamping device 78>
Resin sheets 73 a and 73 b are guided between molds 71 and 72 . The molds 71 and 72 can be separated at the parting surfaces that come into contact when the molds are closed. That is, in the molding process, the molded body 26 is formed using a pair of separable molds 71 and 72 .

The mold 71 is provided with a large number of vacuum suction holes (not shown), so that the resin sheet 73a can be vacuum-sucked and formed into a shape along the inner surface 71b of the cavity of the mold 71. ing. A pinch-off portion 71d is provided to surround the cavity.

The mold 71 has a male protrusion 71e having the same configuration as the male protrusion 24d1. The male projection 71e is provided at a position facing the female projection 9c1. The male projection 71e can be slidably moved with respect to the mold 71 and accommodated in the mold 71. As shown in FIG.

As shown in FIG. 19, the mold 71 has a body portion 71f and a pair of movable portions 71g that can move relative to the body portion 71f. The body portion 71f is provided with projections 71f1 corresponding to the cutting line 26c and the parting line 26f. The movable portion 71g is provided with a protrusion 71g1 that can be engaged with the resin sheets 73a and 73b. The protrusion 71f1 has a left line protrusion 71f1l and a right line protrusion 7f1r along the left line 26cl and right line 26cr of the cutting line 26c. The movable portion 71g is separated from the main body portion 71f along the outer edges of the left line projection 71f1l and the right line projection 7f1r.

The mold 72 is provided with a large number of vacuum suction holes (not shown), so that the resin sheet 73b can be vacuum-sucked and formed into a shape along the inner surface 72b of the cavity of the mold 72. ing. A pinch-off portion 72d is provided to surround the cavity.

As shown in FIG. 18, the lower burr clamping device 78 is arranged below the molds 71 and 72 and comprises clamping members 78a and 78b. The clamping members 78a and 78b are configured to be movable in the same direction as the opening and closing directions of the molds 71 and 72, respectively. When the molded body 26 is removed from the molds 71 and 72, the lower burr clamping device 78 cannot take out the molded body 26 well if it remains fitted in one of the molds. (see FIG. 23) to force the compact 26 to be positioned at the center of the molds 71 and 72 when the molds are opened.

<Details of molding process>
Next, the molding process will be described with reference to FIGS. 18 to 21. FIG. The molding process includes a skin material mounting process, a hanging process, a shaping process, a core material welding process, and a mold closing process.

Skin Material Mounting Process In the skin material mounting process, the skin material 4 held by the female projection 9c1 of the insertion device 9 is moved to the male projection 71e of the mold 71, thereby moving the skin material 4 to the mold 71. to be worn.

This movement can be performed in the same manner as the movement of the skin material 4 from the male projection 24d1 to the female projection 9c1 (see FIG. 17). That is, after the female projection 9c1 and the male projection 71e are opposed to each other, they are engaged, and in this state, the skin material 4 is pushed by the end surface of the cylindrical portion 9c2, thereby pushing the skin material 4 into the shaft of the male projection 71e. can be moved to the department.

Drooping Process In the drooping process, resin sheets 73a and 73b formed by extruding a molten resin 61a through a slit of a T-die 68 and drooping are drooped between molds 71 and 72, as shown in FIG. The resin sheet 73a is suspended between the core material 3 and the skin material 4. As shown in FIG. The resin sheet 73b is suspended between the insertion device 9 and the mold 72. As shown in FIG. In this embodiment, direct vacuum forming is performed using the resin sheets 73a and 73b extruded from the T-die 68 as they are, so the resin sheets 73a and 73b may be cooled to room temperature and solidified before forming. Also, the solidified resin sheets 73a and 73b are not heated before molding.

Shaping Step In the shaping step, the resin sheets 73a and 73b are vacuum-sucked by the molds 71 and 72 to shape the resin sheets 73a and 73b. In the mold 71, the resin sheet 73a is formed into a shape along the contour of the inner surface 71b of the cavity. The resin sheet 73b is formed into a shape along the inner surface 72b of the cavity. The timing of shaping the resin sheets 73a and 73b may be different. good.

After the shaping process and before the mold closing process, the male projection 71e is preferably slid to be housed in the mold 71 . This prevents the male projection 71 e from interfering with the mold 72 . The sliding movement of the male projection 71e is preferably performed before the core material welding step. This can prevent interference between the holding device 13 and the male projection 71e.

- Core Material Welding Process In the core material welding process, the core material 3 is welded to the resin sheet 73a. The core material 3 can be welded to the resin sheet 73a by moving the insertion device 9 toward the resin sheet 73a. After the core material 3 is welded to the resin sheet 73a, the inserting device 9 is moved to a position outside the moving trajectories of the molds 71 and 72.

The timing of arranging the core material 3 between the resin sheets 73a and 73b is not limited, and the core material 3 may be arranged between the resin sheets 73a and 73b in the hanging process or the shaping process. Also, the core material 3 may be welded to the resin sheet 73b first.

·Mold Closing Process In the mold closing process, the molds 71 and 72 are closed by moving the molds 71 and 72 in the directions of arrows C1 and C2 in FIG. As a result, the resin sheets 73a and 73b are compressed and welded at the portions corresponding to the protrusions 71f1 and 71g1 to form the molded body 26 shown in FIG.

<Details of the first cutting step>
A 1st cutting process is demonstrated using FIG.19, FIG.21 and FIG.22.

Before the molds 71 and 72 are opened after the molding process, the molded product main body 26a is engaged with the main body portion 71f of the mold 71, and the large burr 26b is a projection provided on the movable portion 71g of the mold 71. 71g1 is engaged. In this state, as shown in FIG. 22A, when the lower side of the movable portion 71g is tilted away from the main body portion 71f, the molded body 26 is torn from the lower side along the left line 26cl and the right line 26cr of the cutting line 26c. start to be cut like this. Next, as shown in FIG. 22B, when the movable portion 71g is moved so that the upper side of the movable portion 71g is separated from the main body portion 71f, the tear of the molded body 26 progresses upward, and the first cutting step is performed. complete.

2-5. Molded Body Taking Out Process In the molded body taking out process, as shown in FIG. It is removed from the molds 71 and 72 and transferred to the holding device 13 .

The clamping device 12 is configured to be driven by a drive mechanism (not shown). As shown in FIG. 23, the clamping device 12 clamps the compact 26 above the molds 71 and 72 while the molds 71 and 72 are closed. In other words, the clamping device 12 clamps the upper burr 26bu of the compact 26 . In this state, molds 71 and 72 are opened as shown in FIG. At this time, there is a risk that the molded body 26 will be fitted into either of the molds 71 and 72. However, in the present embodiment, the lower burr clamping device 78 clamps the lower burr 26bb. It smoothly separates from the molds 71 and 72 without being fitted into the molds 71 and 72.例文帳に追加The clamping device 12 then moves the molded body 26 towards the holding device 13 . As shown in FIGS. 21 and 24B, the compact 26 is cut along the left line 26cl and the right line 26cr of the cutting line 26c. On the other hand, the molded body 26 is not cut along the upper line 26cu and the lower line 26cb of the cutting line 26c. If the molded body 26 is cut along either the upper line 26cu or the lower line 26cb, the molded body body 26a tends to swing against the large burrs 26b, making it difficult to handle. At this time, the molded body 26 is cut only along the left line 26cl and the right line 26cr, so that the molded body 26 can be easily handled.

2-6. Holding Step In the holding step, the molded body 26 is held by the holding device 13 .

<Configuration of Holding Device 13>
As shown in FIG. 25, the holding device 13 includes a holding base 13b, a rotating mechanism 13c, and a holding mechanism 13e. As shown in FIG. 3, the rotation mechanism 13c is fixed on the carrier 13d, and the carrier 13d is configured to be movable along the carrier line 13a.

The rotating mechanism 13c includes a base 13c1, a first rotating member 13c2, and a second rotating member 13c3. The rotating mechanism 13c includes first and second rotating mechanisms. The first rotating member 13c2 rotates around the first rotating shaft 13c4 parallel to the Y-axis with respect to the base 13c1 (first rotating mechanism). The second rotating member 13c3 rotates relative to the first rotating member 13c2 about a second rotating shaft 13c5 orthogonal to the first rotating shaft 13c4 (second rotating mechanism). The rotating mechanism 13c is configured by, for example, a biaxial robot. The holding base 13b is connected to the second rotating member 13c3. Therefore, the holding table 13b can be rotated by operating the rotating mechanism 13c.

The holding base 13b includes a base 13b1, a pair of connecting members 13b2, and a pair of arms 13b3. The base 13b1 and the arm 13b3 are connected via a connecting member 13b2. The base 13b1 is arranged between the pair of connecting members 13b2. An arm 13b3 is connected to each connecting member 13b2. The connecting member 13b2 is configured to be rotatable with respect to the base 13b1 around a rotating shaft 13b4. The arm 13b3 is configured to be rotatable with respect to the connecting member 13b2 about a rotating shaft 13b5. Therefore, the arm 13b3 is configured to be rotatable with respect to the base 13b1.

The holding table 13b has a holding surface 13f and holds the compact 26 on the holding surface 13f. As shown in FIG. 34, the holding surfaces of the base 13b1, the connecting member 13b2, and the arm 13b3 are referred to as holding surfaces 13f1, 13f2, and 13f3, respectively.

The state of the holding table 13b changes between a planar state, a folded state, and a burr-ejecting state. In the planar state, the holding surfaces 13f1, 13f2, and 13f3 are flush with each other. As shown in FIGS. 33B and 34A, the folded state is a state in which the connecting member 13b2 rotates with respect to the base 13b1 and the arm 13b3 rotates with respect to the connecting member 13b2, and the large burrs 26b are folded. , the holding table 13b is folded. As shown in FIG. 34D, the burr discharging state is a state in which the holding surfaces 13f1 and 13f2 are flush with each other and the arm 13b3 is rotated with respect to the connecting member 13b2. 17, the holding base 13b is put into a burr discharging state.

The holding mechanism 13e includes a base 13e1, a rod 13e2, and a pressing portion 13e3. The molded body 26 can be held by sandwiching the molded body 26 between the pressing portion 13e3 and the holding table 13b. The base 13e1 is fixed to the holding table 13b. The rod 13e2 is arranged to extend perpendicularly to the holding surface 13f, and is configured such that the amount of protrusion from the base 13e1 and the holding surface 13f (that is, the extension and contraction of the rod 13e2) can be adjusted. The pressing portion 13e3 is fixed to the rod 13e2. Therefore, the distance between the pressing portion 13e3 and the holding surface 13f can be adjusted. Also, the rod 13e2 is rotatable about its central axis with respect to the base 13e1. Therefore, the pressing portion 13e3 is configured to be rotatable around the rod 13e2.

The holding mechanism 13e can switch between a standby state, a ready state, an overlapping state, and a pressing state by extending and contracting the rod 13e2 and rotating the pressing portion 13e3. In the standby state and the preparation state, the pressing portion 13e3 does not overlap the holding surface 13f when the holding surface 13f is viewed from a direction perpendicular to the holding surface 13f (hereinafter referred to as "viewed from the holding surface"). are arranged as follows. In the standby state, the rod 13e2 is contracted. In the ready state, the rod 13e2 is in an extended state rather than in the contracted state. In the overlapping state and the pressing state, the pressing portion 13e3 is arranged so as to overlap the holding surface 13f when viewed from the holding surface. The overlapping state is a state in which the rod 13e2 is in an extended state and the holding portion 13e3 does not hold down the formed body 26. The holding state is a state in which the rod 13e2 is contracted from the overlapping state and the formed body 26 is held by the holding portion 13e3. It is in a pressed state.

As shown in FIG. 26, in the standby state, the upper surfaces 13e21 and 13e31 of the rod 13e2 and the pressing portion 13e3 are lower than the holding surface 13f. More specifically, the rod 13e2 of the holding mechanism 13e provided on the base 13b1 and the upper surfaces 13e21 and 13e31 of the pressing portion 13e3 are lower than the holding surface 13f1, and the holding surface provided on the arm 13b3 is lower than the holding surface 13f1. The rod 13e2 of the mechanism 13e and the upper surfaces 13e21 and 13e31 of the pressing portion 13e3 are lower than the holding surface 13f3. According to such a configuration, interference between the holding mechanism 13e and the large burrs 26b is suppressed when the large burrs 26b are folded.

When pressing the compact 26, the state of the holding mechanism 13e is changed in the order of the preparation state, the overlapping state, and the pressing state. When releasing the pressing of the compact 26, the state of the holding mechanism 13e is changed in the order of the pressing state, the overlapping state, and the ready state. A transition from the ready state to the standby state or vice versa may be made as needed. By pressing and releasing the molded body 26 in this way, the molded body 26 can be properly held.

The holding mechanism 13e is classified into an upper holding mechanism 13eu, a central holding mechanism 13ec, and a lower holding mechanism 13eb. The upper holding mechanism 13eu and the lower holding mechanism 13eb are respectively arranged above and below the central holding mechanism 13ec in a state where the holding surface 13f is erected as shown in FIG. The central holding mechanism 13ec is provided on the base 13b1. The upper holding mechanism 13eu and the lower holding mechanism 13eb are provided on the arm 13b3.

As shown in FIG. 21, when the large burr 26b is divided into an upper burr 26bu, a central burr 26bc, and a lower burr 26bb, as shown in FIG. hold an upper burr 26bu, a central burr 26bc and a lower burr 26bb, respectively. The central holding mechanism 13ec holds the molded body 26a before the molded body 26a is separated.

Since the central burr 26bc is entirely or mostly sandwiched between the molds 71 and 72, the thickness of the central burr 26bc is unlikely to increase. The lower burr 26bb includes a portion where the resin sheets 73a and 73b extend below the metal molds 71 and 72. This portion has an irregular shape, and the resin sheets 73a and 73b are shaped when the resin sheets 73a and 73b are shaped. are pulled toward the molds 71 and 72, the thickness (in other words, the distance between the resin sheets 73a and 73b) tends to increase. Therefore, in order to prevent the arm 13b3 of the lower holding mechanism 13eb from interfering with the lower burr 26bb, as shown in FIG. ing.

Moreover, since the upper burr 26bu also includes a portion not sandwiched between the molds 71 and 72, the thickness tends to increase. However, since the upper burr 26bu is sandwiched by the clamping device 12, it is less likely to have an irregular shape like the lower burr 26bb. Therefore, the pressing portion 13e3 of the upper holding mechanism 13eu may have the same length as the pressing portion 13e3 of the central holding mechanism 13ec, or may be shorter.

<Method of Holding Molded Body 26>
First, as shown in FIG. 27A, the holding table 13b is flattened, the holding surface 13f is erected so as to be substantially parallel to the molded body 26, and all the holding mechanisms 13e are ready. In this state, the compact 26 is brought closer to the holding surface 13f.

In a state in which the molded body 26 is closer to the holding surface 13f than the pressing portion 13e3 of the central holding mechanism 13ec, the pressing portion 13e3 is rotated to bring the central holding mechanism 13ec into an overlapping state, and further, the central holding mechanism 13ec is placed in an overlapping state. By contracting the rod 13e2 into a holding state, the holding portion 13e3 holds the compact 26 to the state shown in FIG. 27B. At this point, the upper holding mechanism 13eu and the lower holding mechanism 13eb remain ready.

Next, the upper holding mechanism 13eu and the lower holding mechanism 13eb are brought into the state shown in FIG. 28A by sequentially shifting the overlapping state and the pressing state. At this point, the compact 26 is held by all the holding mechanisms 13e.

By the way, the length of the rod 13e2 of the central holding mechanism 13ec in the overlapping state is longer than the length of the rods 13e2 of the upper holding mechanism 13eu and the lower holding mechanism 13eb. By configuring in this way, even when the molded body 26 is separated from the holding surface 13f to some extent, the molded body 26 can be pressed against the holding surface 13f. On the other hand, since the upper holding mechanism 13eu and the lower holding mechanism 13eb start to operate while the central holding mechanism 13ec is pressing the molded body 26 against the holding surface 13f, there is no need to lengthen the rod 13e2. Therefore, for the upper holding mechanism 13eu and the lower holding mechanism 13eb, the time required for operation is shortened by shortening the rod 13e2 in the overlapping state.

Next, after the clamping device 12 is separated from the compact 26, the first rotating member 13c2 is rotated with respect to the base 13c1 to rotate the holding table 13b so that the holding surface 13f is opened as shown in FIG. is the first horizontal state in which is horizontal. In this manner, the holding table 13b is rotated by the rotating mechanism 13c (more specifically, the first rotating mechanism) when the holding process shifts to the later-described separating process. At this time, the position is adjusted by moving the carrier 13d to which the rotating mechanism 13c is fixed in the direction (+X direction) approaching the burr throwing device 17 along the carrier line 13a.

By the way, if the clamping device 12 is removed in the state shown in FIG. 28A, the upper burr 26bu may bend due to gravity and overlap the compact main body 26a. In such a state, there is a problem that it is difficult to carry out a separation step, which will be described later.

Therefore, in this embodiment, while the state shown in FIG. 28A changes to the state shown in FIG. 29, as shown in FIG. A process of removing the powder from the main body 26a is performed.

Next, as shown in FIG. 31A, by rotating the second rotating member 13c3 by 90 degrees with respect to the first rotating member 13c2, the holding base 13b is rotated in the horizontal plane to the second horizontal state. The purpose of the second horizontal state is to make the moving direction of the head 27 provided on the manipulator 6 coincide with the transport direction of the transport line 13a when performing the second cutting process by the manipulator 6, so that the head 27 can move. One is to reduce the space to be secured, and another is to smoothly perform the burr discharging process, which will be described later.

2-6. Separation Step In the separation step, the molded body 26a is separated from the molded body 26, leaving a large burr 26b on the holding table 13b. The separating step includes a second cutting step and a conveying step. This step can be performed using the manipulator 6 .

<Configuration of Manipulator 6>
The manipulator 6 has a head 27 shown in FIG. 30 at its tip. As shown in FIG. 30, the head 27 includes a base 27a, a suction pad 27b, an imaging section 27c, and a cutter 27d. Each member is held by a base 27a.

The suction pad 27b is used to suck and hold the molded body 26a after separation. The suction pad 27b is configured such that the amount of protrusion from the base 27a can be adjusted. The number of suction pads 27b required to hold the molded body 26a may be provided, and in this embodiment, six suction pads are provided. The suction pads 27b have a bellows shape like the suction pads 24b of the head 24, and even if there is a height difference in the area where the suction pads 27b suck, the molded body body 26a can be reliably sucked by all the suction pads 24b. be able to.

The imaging unit 27c has a function of capturing an image of the molded body 26a and recognizing the position of the identification shape 26g (see FIG. 31B) provided on the molded body 26a. The cutter 27d is used to cut the compact 26 along the upper line 26cu and the lower line 26cb. The cutter 27d is configured such that the amount of protrusion from the base 27a can be adjusted. The identification shape 26g is, for example, a characteristic concave-convex structure provided on the molded body main body 26a.

<Second cutting step>
The second cutting step is performed by cutting the molded body 26 along the upper line 26cu and the lower line 26cb shown in FIG. 21 to separate the molded body 26 into the molded body body 26a and the large burrs 26b.

Since the molded body 26 is not accurately positioned on the holding table 13b, the exact positions of the upper line 26cu and the lower line 26cb are not determined. Therefore, the imaging unit 27c recognizes the position of the identification shape 26g, determines the positions of the upper line 26cu and the lower line 26cb based on the recognized position, and, as shown in FIG. The second cutting step is performed by moving the cutter 27d along the . If either the upper line 26cu or the lower line 26cb is cut in the first cutting step, the large burr 26b is likely to overlap the compact body 26a, and in this case, it becomes difficult to recognize the position of the identification shape 26g. However, in the present embodiment, neither the upper line 26cu nor the lower line 26cb are cut in the first cutting step, so such a problem does not occur.

Alternatively, after cutting along one of the upper line 26cu and the lower line 26cb, the holder 13b may be rotated 180 degrees in the horizontal plane to cut along the other of the upper line 26cu and the lower line 26cb. good. In this case, since the amount of movement of the head 27 is reduced, it is possible to work in a narrow space.

<Conveyance process>
The conveying step is carried out by sucking and holding the molded body 26a with the suction pad 27b and conveying it to the conveyor 28. As shown in FIG. If the central holding mechanism 13ec is in the pressing state, the compact body 26a cannot be conveyed. Therefore, as shown in FIG. conduct. After conveying the compact main body 26a, the central holding mechanism 13ec is put in the pressing state, and the pressing portion 13e3 presses the central burr 26bc. The central holding mechanism 13ec holds the compact main body 26a with the pressing portion 13e3 before the transporting process, and presses the central burr 26bc with the pressing portion 13e3 after the transporting process. The compact main body 26a and the central burr 26bc have different thicknesses, and in order to be able to appropriately hold these two types of members with different thicknesses, the lower limit of the clamp cylinder constituting the central holding mechanism 13ec is Do not operate the limit switch.

2-7. Burr Removal Process In the flash removal process, large burrs 26b left on the holding table 13b in the separation process are removed. The deburring process includes a folding process, a discharging process, an ascending process, and a loading process.

<Folding process>
In the folding step, the large burrs 26b placed on the holding table 13b are folded so that the large burrs 26b can be easily handled. The folding process includes a preliminary folding process, a returning process, and a main folding process. At the start of the folding process, the large burrs 26b are placed across the base 13b1, the pair of connecting members 13b2, and the pair of arms 13b3.

In the pre-folding step, the holding mechanism 13e (not shown in FIGS. 33 to 35) holds the large burr 26b and rotates the connecting member 13b2 and the arm 13b3 to fold the holding table 13b. As a result, as shown in FIG. 33B, the large burrs 26b are folded to form creases 26h in the large burrs 26b. As shown in FIG. 34A, the angle α between the holding surface 13f1 of the base 13b1 and the holding surface 13f3 of the arm 13b3 in the folded state is, for example, 3 to 45 degrees, preferably 8 to 20 degrees. Specifically, this angle α is, for example, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 15, 20, 25, 30, 35, 40, 45 degrees, It may be in a range between any two of the numerical values exemplified here. The angle β between the holding surface 13f1 of the base 13b1 and the holding surface 13f2 of the connecting member 13b2 is preferably 70 to 110 degrees, more preferably 80 to 100 degrees. Specifically, this angle β is, for example, 70, 75, 80, 85, 90, 95, 100, 105, 110 degrees, even if it is within the range between any two of the numerical values exemplified here. good. In this embodiment, the angle α is 13 degrees and the angle β is 90 degrees.

Although it is possible to fold the large burrs 26b by rotating only the arm 13b3, it is easier to reduce the angle α by rotating both the connecting member 13b2 and the arm 13b3.

In the pre-folding step, the connecting member 13b2 and the arm 13b3 are rotated in a state where the crease 26h is not formed on the large burr 26b. Therefore, if the connecting member 13b2 and the arm 13b3 are rotated without fixing the large burr 26b to the holding table 13b, the large burr 26b will not be folded and will be lifted by the arm 13b3, and the large burr 26b will not be properly folded. There is a risk that it will not. Therefore, in the pre-folding step, the connecting member 13b2 and the arm 13b3 are rotated while the holding mechanism 13e holds the large burr 26b.

Moreover, although the large burr 26b may be held by at least one holding mechanism 13e, the upper burr 26bu, the central burr 26bc, and the lower burr 26bb are held by the upper holding mechanism 13eu, the central holding mechanism 13ec, and the lower holding mechanism 13eb. is preferably retained. In this case, the risk of the large burr 26b being lifted by the arm 13b3 is further reduced.

In the returning process, the connecting member 13b2 and the arm 13b3 are rotated in a direction opposite to that in the pre-folding process to increase the angle α. Preferably, in the returning step, the connecting member 13b2 and the arm 13b3 are rotated until the angle α becomes 180 degrees. This step is performed while the large burr 26b is held by the holding mechanism 13e, and the folded large burr 26b is unfolded as the arm 13b3 rotates.

In the main folding step, the holding base 13b is folded by rotating the connecting member 13b2 and the arm 13b3 in a state in which the holding of the large burr 26b by the holding mechanism 13e is released. Since the returning process is performed, the holding of the large burr 26b by the holding mechanism 13e can be easily released. Further, after the large burrs 26b are expanded in the returning process, the large burrs 26b are folded at the positions of the creases 26h formed in the pre-folding process. It becomes difficult to restore to a state where it is not. In the main folding process, the holding mechanism 13e is preferably in a standby state. In this case, interference between the holding mechanism 13e and the large burr 26b can be avoided.

The angles α and β in the main folding step may be the same as in the pre-folding step or may be smaller than in the pre-folding step. In the main folding step, the folding is performed in a state in which the holding of the large burrs 26b by the holding mechanism 13e is released, so it is easy to reduce the angle α.

When folding the large burr 26b, the connecting member 13b2 and arm 13b3 on the upper burr 26bu side and the connecting member 13b2 and arm 13b3 on the lower burr 26bb side may be rotated simultaneously or sequentially. . For example, after the connecting member 13b2 and the arm 13b3 on the side of the upper burr 26bu are rotated as shown in FIG. A return process may be performed after rotating.

The connecting member 13b2 and the arm 13b3 on the side of the upper flash 26bu and the connecting member 13b2 and the arm 13b3 on the side of the lower flash 26bb may be rotated symmetrically or asymmetrically. For example, in the example of FIG. 34B, for the left side, the arm 13b3 is rotated with respect to the connecting member 13b2 without rotating the connecting member 13b2 with respect to the base 13b1, and for the right side, with respect to the base 13b1. , the connecting member 13b2 is rotated, and the arm 13b3 is not rotated with respect to the connecting member 13b2. In this case, the positions of the creases 26h formed on the large burrs 26b are different on the left and right sides, and the distance from the left crease 26h to the left end of the large burrs 26b is shorter than the distance from the right crease 26h to the right end of the large burrs 26b. Therefore, by first folding the large burrs 26b at the left crease 26h and then folding the large burrs 26b at the right crease 26h, the folded large burrs 26b are easily gathered neatly.

In order to facilitate the formation of the crease 26h on the large burr 26b, the metal molds 71 and 72 may be provided with projections to compress the resin sheet at the position where the crease 26h is to be formed to reduce the thickness.

As shown in FIG. 34C, the arm 13b3 on the side of the lower burr 26bb may be fitted with a lower burr plate 13g adapted to the lower burr 26bb, and the arm 13b3 on the side of the upper burr 26bu may be fitted with the upper burr 26bu. An upper burr plate 13h may be attached. In this case, even if the large burrs 26b protrude from the holding table 13b, the large burrs 26b can be stably held and folded.

<Ejection process>
In the discharging process, the large burr 26b is discharged from the holding device 13 toward the burr charging device 17. As shown in FIG.

As shown in FIG. 35, the burr throwing device 17 includes a burr receiver 17a for receiving the large burr 26b and an enclosure 17b surrounding it. The burr receiver 17a has a bottom wall 17a1 and a pair of side walls 17a2 rising from the bottom wall 17a1. The enclosure 17b has a back wall 17b1 and a pair of side walls 17b2 perpendicular to the back wall 17b1. Side wall 17a2 is provided along side wall 17b2. The back wall 17b1 is arranged on the back side of the burr receiver 17a when viewed from the holding table 13b. The back wall 17b1 prevents the large burr 26b on the burr receiver 17a from falling to the back side of the burr receiver 17a.

In the discharging step, the large burr 26b placed on the holding table 13b is slid by tilting the holding table 13b and discharged toward the burr receiver 17a. In this manner, the holding table 13b is rotated by the rotating mechanism 13c (more specifically, the first rotating mechanism) when the separating process is shifted to the discharging process.

When the holding base 13b is in the folded state, the friction between the large burrs 26b and the holding base 13b is large, so even if the holding base 13b is tilted, the large burrs 26b are less likely to slip. For this reason, prior to the discharging step, at least one of the connecting member 13b2 and the arm 13b3 is rotated so that the angles α and β are increased, and the holding table 13b is placed in the burr discharging state shown in FIGS. 34D and 35. is preferred. This makes it easier to slide the large burr 26b from the holding base 13b. In this embodiment, the angle α is 103 degrees and the angle β is 180 degrees in the burr removal state.

By the way, if there is a recess on the holding table 13b for relief when the molded body 26 is cut by the cutter 27d, there is a risk that the large burr 26b will be caught in the recess. Since it is not provided on the base 13b, the large burr 26b is not caught.

Since there is a gap between the holding table 13b and the burr receiver 17a, the large burr 26b may drop from the gap when moving the large burr 26b to the burr receiver 17a. In order to prevent such a drop, as shown in FIG. 35, the burr receiver 17a is inclined so that the holding table 13b side becomes higher during discharge. In this case, since the large burr 26b moved to the burr receiver 17a quickly slides to the back side of the burr receiver 17a, it is possible to prevent the large burr 26b from falling from the front side of the burr receiver 17a. Further, since the back wall 17b1 is provided on the back side of the burr receiver 17a, it is possible to prevent the large burr 26b from falling from the back side of the burr receiver 17a. Whether or not the large burr 26b has moved to the burr receiver 17a can be detected by sensors provided on the holding table 13b and the burr receiver 17a.

<Rise process>
As shown in FIG. 36, the rear wall 17b1 is provided with an inlet 17b11 into the crusher 18 at a position higher than the position of the burr receiver 17a in the discharge process. In the lifting process, the burr receiver 17a is lifted toward the inlet 17b11. The burr receiver 17a is lifted substantially vertically by a lifter. When the inlet of the crusher 18 is located at a high position, a large space is required to transport the burrs to the inlet using a conveyor. This makes it possible to feed the large burrs 26b into the crusher 18 in a narrow space.

This lifting process can be performed while the burr receiver 17a is tilted, but in that case, the large burr 26b always rubs against the back wall 17b1, and wears the back wall 17b1. In order to suppress such wear, it is preferable to perform the lifting process with the burr receiver 17a horizontal as shown in FIG.

Also, the large burr 26b can be cooled during this rising process. As a result, the temperature of the large burrs 26b introduced into the crusher 18 is lowered, and deterioration of the crusher 18 is suppressed. Cooling can be performed by blowing air against the large burrs 26b. In order to improve air permeability, the burr throwing device 17 may have a mesh structure at a portion where there is no concern that the large burrs 26b may be caught.

Also, by slowly performing this rising process, it is possible to lengthen the time until the large burrs 26b are thrown into the crusher 18 after the separation process. As a result, when it is detected that the skin material 4 does not exist on the compact body 26a or the cutter 27d is broken in an inspection process included in the main body processing process, which will be described later, the large burrs 26b are It is possible to stop the burr charging device 17 before the burr is charged to 18. From this point of view, it is preferable to perform the rising process over a longer period of time than the inspection process. Moreover, since it is necessary to return the burr receiver 17a to the lower position before the large burr 26b generated in the next cycle is discharged toward the burr receiver 17a, the time for the rising process is preferably 0.9 cycle time or less. , 0.8 cycle time or less is more preferable.

<Injection process>
In the charging step, after the burr receiver 17a is raised to the charging port 17b11, the burr receiver 17a is inclined and the large burrs 26b are charged into the crusher 18 through the charging port 17b11. The pulverizer 18 pulverizes the large burrs 26b to produce a recycled raw material.

2-8. Main Body Processing Process In the main body processing process, an inspection process, a pressing process, an overlapping process, and a post-process are performed on the compact body 26a. As shown in FIG. 37, the inspection process, the pressing process, and the stacking process are carried out by an inspection device 14, a pressing device 15, and a stacking device 16, respectively. The compact body 26a is transported using a conveyor 28 and a feeding device 29. As shown in FIG. 37A and 37C, above the inspection device 14, the compact body 26a is placed on the conveyor 28, and on the stacking device 16 is the compact body 26a produced in the previous cycle. placed.

Conveyor 28 is, for example, a roller conveyor. The feeding device 29 includes a base 29a, a rod 29b, and a tip portion 29c. The rod 29b is configured such that the amount of protrusion from the base 29a can be adjusted. The tip portion 29c is fixed to the tip of the rod 29b. With the molded body 26a placed on the conveyor 28, the rod 29b is extended to push the side of the molded body 26a with the tip 29c, thereby moving the molded body 26a. Instead of using the feeding device 29, the conveyor 28 itself may be driven to move the compact body 26a. Further, the conveyer 28 does not pass through the press device 15, and the compact main body 26a moves in the press device 15 so as to slide on the lower wall 15a shown in FIG.

<Inspection process>
In the inspection process, the inspection device 14 is used to inspect the compact main body 26 a conveyed on the conveyor 28 . Here, a weight inspection and a skin material displacement inspection are performed.

As shown in FIGS. 38A and 38B, the inspection device 14 includes a weighing platform 14a, a weighing device 14b, a sensor 14c, and a lifting device 14d. The lifting device 14d includes a base 14d1 and a rod 14d2. The rod 14d2 is configured such that the amount of protrusion from the base 14d1 can be adjusted. The weighing device 14b is fixed to the rod 14d2. The weighing table 14a is fixed to the weighing device 14b. The weighing device 14b can measure the weight of an object placed on the weighing table 14a. The sensor 14c is fixed to the weighing table 14a. The sensor 14c is configured to be able to measure the reflectance of the upper right and the vicinity of the upper left of the molded body 26a.

As shown in FIG. 38B, when the inspection apparatus 14 is on standby, the upper surface of the weighing table 14a is lower than the upper surface of the conveyor 28 (the surface where the molded body 26a contacts the conveyor 28). In this state, the weighing device 14b cannot measure the weight of the compact body 26a.

At the time of inspection, the inspection apparatus 14 raises the weighing table 14a to support the compact main body 26a on the upper surface of the weighing table 14a, as shown in FIG. 38C. In this state, the weighing device 14b can measure the weight of the compact body 26a.

The molded body 26a is placed so that the skin material 4 faces downward, and the sensor 14c detects that the skin material 4 exists in the upper right and near the upper left of the molded body 26a through the measurement of the reflectance. It is possible to detect whether or not If the absence of the skin material 4 is detected only in either the upper right or the upper left, the molded product body 26a is removed from the conveyor 28 as a defective product. On the other hand, if the skin material 4 does not exist on both the upper right and the upper left, there is a possibility that the skin material 4 may fall and adhere to the large burr 26b. If the skin material 4 is thrown into the crusher 18, the quality of the recycled raw material is lowered, so the burr feeding device 17 is stopped until it is confirmed that the skin material 4 does not adhere to the large burrs 26b.

In the inspection process, it may be inspected whether or not the cutter 27d is broken. This inspection can be performed by confirming whether the length of the cutter 27d is equal to or greater than a reference value. If the length of the cutter 27d is less than the reference value, there is a possibility that the cutter 27d is broken or the cutter 27d is worn and shortened. Therefore, in such a case, the burr throwing device 17 can be stopped so that the broken portion of the cutter 27 d is not thrown into the crusher 18 .

After the inspection process, as shown in FIG. 39A, the weighing table 14a is lowered to place the molded body 26a on the conveyor 28, and in this state, the side of the molded body 26a is pushed with the tip 29c, thereby forming the molded body. The main body 26a is moved toward the press device 15. As shown in FIG.

<Press process>
In the pressing step, the press device 15 is used to press the molded body 26a to improve the planarity of the molded body 26a. As shown in FIG. 39, the press device 15 includes a lower wall 15a, an upper wall 15b, and a pressure device 15c. The pressure device 15c has a base 15c1 and a rod 15c2. The rod 15c2 is configured such that the amount of protrusion from the base 15c1 can be adjusted. The pressing process can be performed by extending the rod 15c2 to press the upper wall 15b against the molded body 26a with the molded body 26a disposed between the lower wall 15a and the upper wall 15b.

After the pressing process, the upper wall 15b is lifted, and then the side surface of the molded body 26a is pushed by the tip portion 29c, thereby moving the molded body 26a toward the stacking device 16. As shown in FIG.

<Overlapping process>
In the stacking step, a stacking device 16 is used to stack a plurality of compact bodies 26a. As shown in FIG. 40, the stacking device 16 includes a pair of cylinder units 16a. Each cylinder unit 16a includes a first base 16a1, a first rod 16a2, a second base 16a3, a second rod 16a4, and a stack guide 16a5. The first base 16a1 is fixed to a member (not shown). The first rod 16a2 extends in the width direction of the conveyor 28, and the amount of protrusion from the first base 16a1 can be adjusted. The second base 16a3 is fixed to the first rod 16a2. The second rod 16a4 extends in the height direction and has an adjustable amount of protrusion from the second base 16a3. The stack guide 16a5 is fixed to the second rod 16a4. With such a configuration, the stack guide 16a5 is movable in the vertical direction and the width direction of the conveyor .

In the state of FIG. 39B, the stack guide 16a5 is in the raised position, and the compact body 26a manufactured in the previous cycle is placed on the stack guide 16a5. In this state, there is a gap larger than the thickness of the compact main body 26a between the lower surface of the stack guide 16a5 and the conveyor 28. As shown in FIG. After the pressing process, the compact main body 26a is pushed by the tip portion 29c and accommodated in the gap between the lower surface of the stack guide 16a5 and the conveyor 28, as shown in FIG. The two compact bodies 26a in FIG. 40 are separated by the stack guide 16a5 and are not stacked at this point.

FIG. 41A shows a state in which the width between the pair of stack guides 16a5 is expanded from the state of FIG. 40 to the width of the compact body 26a or more. In this state, the compact main body 26a placed on the stack guide 16a5 is dropped and stacked on the lower compact main body 26a.

FIG. 41B shows a state in which the pair of stack guides 16a5 are lowered from the state shown in FIG. 41A and the space therebetween is narrowed. When the stack guide 16a5 is lifted from this state, the two compact bodies 26a are lifted by the stack guide 16a5. Between the lower surface of the stack guide 16a5 and the conveyor 28, a gap is provided which is equal to or greater than the thickness of the compact body 26a, and the compact body 26a to be formed in the next cycle is accommodated in this gap.

By repeating the above steps, a plurality of compact bodies 26a can be stacked on the stack guide 16a5.

<Post-process>
In the post-process, the molded body 26a on the stack guide 16a5 is taken out one by one, and the small burrs 26e are removed and the fine burrs remaining on the parting line PL are removed, thereby removing the resin panel 1. obtain. This step can be performed by the operator 21 .

1: resin panel, 2: resin molding, 3: core material, 3a: base, 3a1: recessed portion, 3b: base, 3b1: recessed portion, 3c: reinforcing member, 3c1: upper wall, 3c11: projection, 3c2: lower Wall, 3c21: Protrusion, 3c3: Column, 4: Skin material, 5: First manipulator, 5a: Conveyor, 6: Second manipulator, 6a: Mounting table, 7: Member supply line, 8: Positioning device, 8a : positioning base, 8b: locking portion, 8b1: first locking portion, 8b2: second locking portion, 8c: rotating mechanism, 8c1: base, 8c2: first rotating member, 8c3: second rotating member, 8c4: first rotating shaft, 8c5: second rotating shaft, 8d: pedestal, 9: insertion device, 9a: base, 9b: suction pad, 9c: female holding portion, 9c1: female protrusion, 9c11: shaft portion, 9c12: swelling portion, 9c13: concave portion, 9c2: cylindrical portion, 9c3: base, 10: molding machine,
12: Clamping device, 13: Holding device, 13a: Transfer line, 13b: Holding table, 13b1: Base, 13b2: Connecting member, 13b3: Arm, 13b4: Rotating shaft, 13b5: Rotating shaft, 13c: Rotating mechanism, 13c1: base, 13c2: first rotating member, 13c3: second rotating member, 13c4: first rotating shaft, 13c5: second rotating shaft, 13d: carrier, 13e: holding mechanism, 13e1: base, 13e2: rod, 13e3: pressing portion, 13eb: lower holding mechanism, 13ec: central holding mechanism, 13eu: upper holding mechanism, 13f: holding surface, 13f1: holding surface, 13f2: holding surface, 13f3: holding surface, 13g: lower burr plate, 13h : upper burr plate, 14: inspection device, 14a: weighing table, 14b: weighing device, 14c: sensor, 14d: lifting device, 14d1: base, 14d2: rod, 15: press device, 15a: lower wall, 15b: upper wall, 15c: pressure device, 15c1: base, 15c2: rod, 16: stacking device, 16a: cylinder unit, 16a1: first base, 16a2: first rod, 16a3: second base, 16a4: second rod , 16a5: Stack guide, 17: Burr throwing device, 17a: Burr receiver, 17a1: Bottom wall, 17a2: Side wall, 17b: Enclosure, 17b1: Back wall, 17b11: Throwing port, 17b2: Side wall, 18: Crusher,
20: manufacturing system, 21: operator, 22: core material carrier, 23: skin material carrier, 24: head, 24a: base, 24a1: member mounting surface, 24b: suction pad, 24b1: suction surface, 24c: needle Gripper 24d: Male type holding part 24d1: Male type projection 24d11: Shaft part 24d12: Expansion part 24d2: Cylinder part 24d3: Base 24e: Reinforcing member positioning mechanism 24e1: First base 24e2: 1st rod, 24e3: second base, 24e4: second rod, 25: sensor, 26: compact, 26a: compact main body, 26b: large burr, 26bb: lower burr, 26bc: central burr, 26bu: upper burr , 26c: cutting line, 26cb: lower line, 26cl: left line, 26cr: right line, 26cu: upper line, 26d: molded product, 26e: small burr, 26f: parting line, 26fb: lower line, 26fl: left line, 26fr: right line, 26fu: upper line, 26g: identification shape, 26h: crease, 27: head, 27a: base, 27b: suction pad, 27c: imaging unit, 27d: cutter, 28: conveyor, 29: feed Apparatus 29a: Base 29b: Rod 29c: Tip 30: Heater 61: Raw material resin 61a: Molten resin 62: Hopper 63: Extruder 63a: Cylinder 64: Sheet forming device 67: Accumulator , 67a: cylinder, 67b: piston, 68: T die,
71: first mold, 71b: inner surface, 71d: pinch-off portion, 71e: male projection, 71f: body portion, 71f1: projection, 71f1l: left line projection, 71f1r: right line projection, 71g: movable portion, 71g1: Protrusion 72: Second mold 72b: Inner surface 72d: Pinch-off part 73a: First resin sheet 73b: Second resin sheet 75: Connecting pipe 77: Connecting pipe 78: Lower burr clamping device PL: parting line

Claims (4)

A method for manufacturing a structure,
Equipped with a tilting process,
In the tilting step, by tilting the positioning table, the target member placed on the positioning table is slid to abut against the locking portion, thereby positioning the target member;
The positioning table is configured to be rotatable about first and second rotating shafts,
The first rotation axis and the second rotation axis are orthogonal to each other,
The locking portion includes a first locking portion and a second locking portion,
The tilting step includes a first rotating shaft rotating step and a second rotating shaft rotating step,
In the first rotating shaft rotating step, the target member is slid to come into contact with the first engaging portion by rotating the positioning base about the first rotating shaft;
In the second rotating shaft rotating step, the target member is caused to slide and contact the second locking portion by rotating the positioning base about the second rotating shaft;
The method, wherein the first and second locking portions are provided on the positioning table. A method for manufacturing a structure,
Equipped with a tilting process,
In the tilting step, by tilting the positioning table, the target member placed on the positioning table is slid to abut against the locking portion, thereby positioning the target member;
The positioning table is configured to be rotatable about first and second rotating shafts,
The first rotation axis and the second rotation axis are orthogonal to each other,
The locking portion includes a first locking portion and a second locking portion,
The tilting step includes a first rotating shaft rotating step and a second rotating shaft rotating step,
In the first rotating shaft rotating step, the target member is slid to come into contact with the first engaging portion by rotating the positioning base about the first rotating shaft;
In the second rotating shaft rotating step, the target member is caused to slide and contact the second locking portion by rotating the positioning base about the second rotating shaft;
The method, wherein the target member is a nonwoven fabric. A method according to claim 1 or claim 2 ,
The method, wherein the target member comprises a pair of substrates engaged by an elongate reinforcing member. The method according to any one of claims 1 to 3 ,
A holding step is provided after the tilting step,
In the holding step, the method includes holding and moving the target member with a manipulator while the target member is positioned.

Images