System and method for monitoring operation of metal scrap chopper

Abstract

The present disclosure provides a system and method for monitoring operation of a scrap metal chopper. A method of monitoring operation of a chopper or health of a chopper component includes: setting a profile of a selected parameter of the chopper, wherein the profile includes a nominal value, a tolerance of the nominal value, and a predetermined range of the selected parameter outside the tolerance; obtaining an actual value of the selected parameter; comparing the actual value with the configuration file of the selected parameter; an operating condition of the chopper is determined based on a comparison between the actual value and the profile of the selected parameter. The configuration file is obtained based on experimental data, statistics or machine learning.

Description

Technical Field

[0001] The present disclosure relates to a system and method for monitoring a scrap metal shredder associated with a sheet metal stamping operation. Background Art

[0002] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.

[0003] Sheet metal stamping equipment is typically used to create engineered formed panels by performing forming operations (such as trimming and punching) on ​​flat metal sheets. A scrap shredder is typically located downstream of the sheet metal stamping equipment to receive scrap removed from the forming operation and cut it into small pieces, which are then conveyed to a scrap collection container / station. When the scrap is not properly cut into small pieces, the scrap may clog the chute between the sheet metal stamping equipment and the scrap shredder, causing the sheet metal stamping equipment to be unable to perform the desired forming operation. Typically, the sheet metal stamping equipment must be stopped before the scrap is cleared, resulting in downtime for the sheet metal stamping equipment.

[0004] Problems associated with waste clogging in waste shredders are addressed in the present disclosure. Summary of the invention

[0005] This section provides a general summary of the disclosure and is not a comprehensive disclosure of its full scope or all of its features.

[0006] In one form, a method of monitoring the operation of a shredder or the health of a shredder component is provided, the method comprising: setting a profile for a selected parameter of the shredder, wherein the profile comprises a nominal value, a tolerance for the nominal value, and a predetermined range for the selected parameter outside the tolerance; obtaining an actual value of the selected parameter; comparing the actual value to the profile for the selected parameter; and determining an operating condition of the shredder based on the comparison between the actual value and the profile for the selected parameter.

[0007] In other features, the method further includes determining, based on the comparison, that the shredder is operating under one of a normal condition, a subnormal condition, and an abnormal condition; and determining that the shredder is operating under a subnormal condition when the actual value is within the predetermined range. The selected parameter is selected from the group consisting of: vibration, temperature, and current, torque, and electric power of the motor of the shredder. The actual value of the selected parameter is obtained by a sensor. The sensor is a vibration sensor or a temperature sensor. The predetermined range of the selected parameter can be obtained based on experimental data, statistics, or machine learning. The actual value of the selected parameter is obtained by calculation based on one or more other parameters. The shredder is disposed downstream of a forming device and is configured to cut waste removed from the forming device. The forming device is selected from the group consisting of: a stamping machine, a punching device, and a cutting device. The profile is specific to a process performed by the forming device. The profile is specific to a product formed by the forming device.

[0008] In still other features, the method further comprises: adjusting an operating parameter of the forming apparatus when the actual value is within the predetermined range; and determining, by a controller, that the shredder is operating under abnormal conditions when the actual value is outside the predetermined range. The predetermined range has limits that coincide with limits of the tolerance.

[0009] In another form, a system is provided, the system including a shredder disposed downstream of a forming device and configured to cut waste material generated in the forming device into small pieces. The shredder includes at least one of a sensor for obtaining actual values ​​of parameters selected to be monitored and a parameter determination module. The shredder also includes: a memory configured to store a profile of selected parameters corresponding to a plurality of parts to be formed in the forming device; and a comparison module configured to compare the actual values ​​with the profile to determine the operating condition of the shredder.

[0010] In other features, the configuration files each include a nominal value of the selected parameter, a tolerance of the nominal value, and a predetermined range of deviations of the selected parameter from the tolerance of the nominal value. The comparison module is configured to determine that the shredder is operating in a subnormal condition when the actual value is within the predetermined range. The comparison module is configured to determine that the shredder is operating in an abnormal condition when the actual value deviates from the tolerance of the nominal value and is outside the predetermined range. The comparison module is in communication with a controller of the forming device, such that the controller of the forming device is configured to adjust operating parameters of the forming device according to the operating conditions of the shredder.

[0011] Further areas of applicability will become apparent from the description provided herein.It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] In order that the present disclosure may be better understood, various forms of the present disclosure will now be described by way of example with reference to the accompanying drawings, in which:

[0013] Figure 1 is a schematic diagram of a system for forming a metal sheet into a component having a predetermined shape according to the teachings of the present disclosure; and

[0014] Figure 2 is a flow chart of a method of monitoring operation of a shredder according to the teachings of the present disclosure.

[0015] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. DETAILED DESCRIPTION

[0016] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate the same or corresponding parts and features.

[0017] refer to Figure 1 , a system 20 for forming a metal sheet into a component or product having a predetermined shape according to the teachings of the present disclosure includes a forming device 22 and a shredder 24, which is connected to the forming device 22 via, for example, one or more chutes (not shown). The forming device 22 can be a stamping machine, a punching device, or a cutting device, and is configured to perform one or more forming operations (such as stamping, trimming, and punching) on ​​the metal sheet to form a component having a predetermined shape and size, such as an engineered formed panel. During the forming process, waste is generated in the forming device 22 and conveyed to the shredder 24, which cuts the waste into small pieces and then conveys the waste to a waste collection container or station (not shown).

[0018] The forming apparatus 22 includes a control module 26 (e.g., in the form of one or more controllers) configured to control the operation of the forming apparatus 22. The control module 26 includes a memory 28 and an operating parameter adjustment module 30. The memory 28 is configured to store a plurality of sets of operating parameters corresponding to a plurality of parts to be formed and / or a plurality of forming processes to be performed in the forming apparatus 22. Each set of operating parameters of the forming apparatus 22 is specific to a particular part to be formed by a particular forming process. The operating parameters for forming a particular part also vary depending on the material, size, thickness, and grade of the metal sheet fed into the forming apparatus 22. The operating parameter adjustment module 30 is configured to adjust or update the operating parameters in response to data received from the shredder 24 regarding the operating conditions of the shredder 24, which will be described in more detail below.

[0019] The shredder 24 includes a blade (not shown) for cutting waste material delivered from the forming device 22, at least one bearing 40 for supporting the blade on a housing (not shown) of the shredder 24, at least one motor 42 for driving the blade, and a control module 44 (e.g., in the form of one or more controllers) configured to control the operation of the shredder 24. The control module 44 includes at least one sensor 46, a parameter determination module 48, a comparison module 50, a memory 52, and an alarm generation module 54.

[0020] The control module 44 of the shredder 24 is configured to select parameters of the shredder 24 to be monitored. The sensor 46 is configured to obtain a measurement (i.e., an actual value) of the parameter selected for monitoring (hereinafter referred to as the "selected parameter"), such as vibration, temperature, current, torque, or power of the shredder 24. The sensor 46 may be a vibration sensor for obtaining data related to the vibration of the shredder 24 or a shredder component, or a temperature sensor for measuring the temperature of the shredder 24 or a shredder component. The sensor 46 may be disposed at a location where the sensor 46 is exposed to strong vibration or high temperature, such as near the bearing 30 or the motor 32 of the shredder. However, the sensor 46 may be disposed on the housing or at other locations without departing from the scope of the present disclosure.

[0021] Alternatively, the parameter determination module 48 can be used to calculate the actual value of the selected parameter based on other parameters rather than directly measuring the selected parameter using the sensor 46. For example, when the selected parameter is an electrical load (such as current, torque, or power), the actual value of the selected parameter can be calculated based on other available parameters, thereby eliminating the need to use additional sensors for monitoring. Thus, the actual value of the selected parameter can be obtained by measurement (via the sensor 46) or by calculation (via the parameter determination module 48).

[0022] The memory 52 is configured to store data related to profiles of one or more selected parameters for different job IDs and / or part IDs of the forming apparatus 22. The part ID refers to information about a specific product / component (such as an engineered panel having a desired shape, size, thickness, material, material grade, etc.) to be formed by the forming apparatus 22. The job ID refers to information about a specific operation (including cutting, trimming, and punching) to be performed in the forming apparatus 22. A profile is created corresponding to each job ID and / or part ID. Thus, the profile is specific to a specific job performed in the forming apparatus 22 to ensure optimal operation of the shredder 24 downstream of the forming apparatus 22.

[0023] Each profile includes a nominal value, a tolerance of the nominal value, and a predetermined range outside the tolerance of the nominal value. The predetermined range has a limit that coincides with the limit of the tolerance of the nominal value. The nominal value and the tolerance of the nominal value represent values ​​or ranges of the selected parameter, indicating that the shredder 24 operates under an optimal operating condition without any problems. The predetermined range of the selected parameter represents a range of the selected parameter in which the shredder 24 is not under an optimal operating condition but under an acceptable (i.e., sub-normal) condition with some problems. Under the sub-normal condition, the shredder 24 can still perform the desired cutting function, but due to some problems in the shredder 24 (e.g., a slight blockage of waste material in the shredder 24), the motor of the shredder 24 may be required to consume more power or current. The profile includes the nominal value, the tolerance of the nominal value, and the predetermined range of the selected parameter, which can be obtained based on experimental data, statistics, or machine learning.

[0024] The comparison module 50 is configured to compare the actual value of the selected parameter with the corresponding configuration file to determine whether the actual value of the selected parameter is within the tolerance of the nominal value (indicating a normal operating condition of the shredder), within the predetermined range (indicating a sub-normal operating condition of the shredder), or outside the tolerance of the nominal value and outside the predetermined range (indicating an abnormal operating condition of the shredder).

[0025] The alarm generation module 54 is configured to generate and send an alarm indicating the operating condition of the shredder 24. When the comparison module 50 determines that the actual value of the selected parameter deviates from the tolerance of the nominal value but is within a predetermined range, the comparison module 50 sends a signal to the alarm generation module 54, which in turn generates a first alarm indicating that the shredder is operating in a subnormal condition.

[0026] The subnormal condition may be caused by a minor blockage in the shredder or an incorrect setting of the operating parameters of the forming device 22. Upon receiving the first alarm, the operator can check the condition of the shredder 24 to resolve any possible problems that may gradually cause the shredder 24 to fail. For example, the scrap may arrive at the shredder 24 at a unique location and cannot be properly cut into small pieces as needed. In response to the first alarm, the operator can change the location of the scrap to resolve the potential blockage problem. In addition, the comparison module 50 is also configured to send a signal to the operating parameter adjustment module 30 of the forming device 22 to adjust the operating parameters of the forming device 22. By changing the operating parameters of the forming device 22, the metal sheet can be cut or trimmed in the forming device 22 in the following manner: scrap with a shape or position that can be relatively easily transported to the shredder 24 and cut in the shredder is produced.

[0027] If the comparison module 50 determines that the actual value deviates significantly from the tolerance of the nominal value to the extent that it falls outside of the predetermined range, the comparison module 50 sends a signal to the alarm generation module 54, which then generates a second alarm indicating that the shredder 24 is operating under abnormal conditions and may require maintenance.

[0028] refer to Figure 2 The method 70 for monitoring the operation of a shredder or the health of a shredder component begins by setting a profile of a parameter of the shredder 24 to be monitored in step 72. The parameter of the shredder 24 to be monitored may be vibration, temperature, or electrical load (e.g., current, torque, power) of a motor driving the blades of the shredder 24. Next, an actual value of a selected parameter of the shredder 24 is obtained in step 74. The actual value may be a measured value obtained by a sensor or a calculated value obtained by a parameter determination module 48 of the shredder 24. Then, in step 76, the actual value of the selected parameter is compared with the profile of the selected parameter. In step 78, the comparison module 50 of the shredder 24 determines whether the actual value of the selected parameter is within a tolerance of a nominal value. If the actual value is within a tolerance of the nominal value, the comparison module 50 determines that the shredder 24 is operating under optimal operation or normal conditions. The method ends in step 80.

[0029] If the actual value is outside the tolerance of the nominal value, the comparison module 50 determines whether the actual value is within the predetermined range in step 82. If the actual value is outside the tolerance of the nominal value but within the predetermined range, the comparison module 50 determines that the shredder 24 is operating in a subnormal condition. In step 84, a first alarm is generated indicating that the shredder is operating in a subnormal condition.

[0030] In step 86, the comparison module 50 of the shredder is further configured to send a signal to the controller 26 of the forming device 22 so that the controller 26 of the forming device 22 can adjust the operating parameters of the forming device 22. The method then returns to step 72 to reset the profile of the selected parameters of the shredder 24 in response to the adjusted operating parameters of the forming device 22, and continue to monitor the selected parameters of the shredder 24 to determine when the shredder 24 is operating in a normal condition, a sub-normal condition, or an abnormal condition.

[0031] If it is determined in step 82 that the actual value is outside the predetermined range, the comparison module 50 determines that the shredder 24 is operating under abnormal conditions. In step 88, the comparison module 50 generates a second alarm indicating that the shredder 24 is operating under abnormal conditions and may require maintenance. In response to the second alarm, the operator should check the shredder 24 to resolve any potential problems that would otherwise cause the shredder 24 to fail. The second alarm may also be sent to the forming device 22 to stop or slow down the operation of the forming device 22 until the problem is resolved. The method ends in step 80.

[0032] The shredder and method of monitoring the operation of the shredder according to the present disclosure can identify the operating condition of the shredder or the health of the shredder components by monitoring selected parameters before the shredder fails. The control module of the shredder uses sensors or parameter determination modules to obtain measured or calculated values ​​of the selected parameters to be monitored, and compares the measured or calculated values ​​with job or part specific profiles to determine whether the shredder is operating in an optimal operating condition, a subnormal condition, or an abnormal condition before the shredder fails. In addition, the operating parameters of the forming device 22 can be adjusted accordingly in response to the identified operating condition of the shredder, so that the entire system including the forming device and the shredder operates more efficiently. This monitoring also ensures the correct operation of the shredder and reduces any downtime events caused by waste blockage.

[0033] Unless otherwise expressly indicated herein, all numerical values ​​indicating mechanical / thermal properties, composition percentages, dimensions and / or tolerances or other characteristics when describing the scope of the present disclosure should be understood to be modified by the word "about" or "approximately". Such modifications are desirable for a variety of reasons, including: industrial practice; material, manufacturing and assembly tolerances; and testing capabilities.

[0034] As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A or B or C), using a non-exclusive logical "or", and should not be construed to mean "at least one of A, at least one of B, and at least one of C."

[0035] In this application, the terms "controller" and / or "module" may refer to, be part of, or include: an application-specific integrated circuit (ASIC); a digital, analog, or mixed analog / digital discrete circuit; a digital, analog, or mixed analog / digital integrated circuit; a combinatorial logic circuit; a field programmable gate array (FPGA); a processor circuit (shared, dedicated, or group) that executes code; a memory circuit (shared, dedicated, or group) that stores code executed by the processor circuit; other suitable hardware components that provide the described functionality (e.g., an operational amplifier circuit integrator as part of a heat flux data module); or a combination of some or all of the above, such as in a system on a chip.

[0036] The term memory is a subset of the term computer-readable medium. The term computer-readable medium as used herein does not encompass transient electrical or electromagnetic signals propagated through a medium (such as on a carrier wave); therefore, the term computer-readable medium may be considered to be tangible and non-transitory. Non-limiting examples of non-transitory tangible computer-readable media are non-volatile memory circuits (such as flash memory circuits, erasable programmable read-only memory circuits, or mask read-only circuits), volatile memory circuits (such as static random access memory circuits or dynamic random access memory circuits), magnetic storage media (such as analog or digital tape or hard drives), and optical storage media (such as CDs, DVDs, or Blu-ray discs).

[0037] The apparatus and methods described in this application may be implemented partially or completely by a special-purpose computer, which is created by configuring a general-purpose computer to perform one or more specific functions embodied in a computer program. The functional blocks, flow chart components, and other elements described above are used as software specifications, which can be translated into a computer program by routine work of a technician or programmer.

[0038] The description of the present disclosure is merely exemplary in nature, and thus, variations that do not depart from the essence of the present disclosure are intended to be within the scope of the present disclosure. Such variations should not be regarded as a departure from the spirit and scope of the present disclosure.

[0039] According to the present invention, a method for monitoring the operation of a shredder comprises: setting a profile of a selected parameter of the shredder, wherein the profile comprises a nominal value, a tolerance of the nominal value, and a predetermined range of the selected parameter outside the tolerance; obtaining an actual value of the selected parameter; comparing the actual value with the profile of the selected parameter; and determining an operating condition of the shredder based on the comparison between the actual value and the profile of the selected parameter.

[0040] In one aspect of the invention, the method includes determining, based on the comparison, that the shredder is operating in one of a normal condition, a sub-normal condition, and an abnormal condition.

[0041] In one aspect of the invention, the method comprises determining that the shredder is operating in a subnormal condition when the actual value is within the predetermined range.

[0042] In an aspect of the invention, the selected parameter is selected from the group consisting of: vibration, temperature and current, torque and electrical power of a motor of the shredder.

[0043] In one aspect of the invention, said actual value of said selected parameter is obtained by a sensor.

[0044] In one aspect of the invention, the sensor is a vibration sensor or a temperature sensor.

[0045] In one aspect of the invention, the profile is obtained based on experimental data, statistics or machine learning.

[0046] In one aspect of the invention, said actual value of said selected parameter is obtained by calculation based on one or more other parameters.

[0047] In one aspect of the invention, the shredder is disposed downstream of the forming device and is configured to cut waste material removed from the forming device.

[0048] In one aspect of the invention, the forming device is selected from the group consisting of: a punching machine, a punching device, a cutting device.

[0049] In one aspect of the invention, said profile is specific to the process performed by said forming apparatus.

[0050] In one aspect of the invention, said profile is specific to the product formed by said forming apparatus.

[0051] In one aspect of the invention, the method comprises adjusting an operating parameter of the forming apparatus when the actual value is within the predetermined range.

[0052] In one aspect of the invention, the method includes determining, by a controller, that the shredder is operating under an abnormal condition when the actual value is outside the predetermined range.

[0053] In one aspect of the invention, said predetermined range has limits which coincide with the limits of said tolerance.

[0054] According to the present invention, a system is provided, the system having: a shredder, the shredder being arranged downstream of a forming device and being configured to cut waste generated in the forming device into small pieces, the shredder comprising: at least one of a sensor and a parameter determination module for obtaining actual values ​​of parameters selected to be monitored; a memory, the memory being configured to store a profile of selected parameters corresponding to a plurality of parts to be formed in the forming device; and a comparison module, the comparison module being configured to compare the actual values ​​with the profile to determine the operating condition of the shredder.

[0055] According to an embodiment, the configuration files each comprise a nominal value of the selected parameter, a tolerance of the nominal value and a predetermined range within which the selected parameter deviates from the tolerance of the nominal value.

[0056] According to an embodiment, the comparison module is configured to determine that the shredder is operating in a subnormal condition when the actual value is within the predetermined range.

[0057] According to an embodiment, the comparison module is configured to determine that the shredder is operating under abnormal conditions when the actual value deviates from the nominal value by the tolerance and is outside the predetermined range.

[0058] According to an embodiment, the comparison module is in communication with a controller of the forming device such that the controller of the forming device is configured to adjust operating parameters of the forming device according to the operating conditions of the shredder.

Claims

1. A method of monitoring the operation of a shredder, comprising: setting a profile of a selected parameter of the shredder, wherein the profile includes a nominal value, a tolerance of the nominal value, and a predetermined range of the selected parameter outside of the tolerance; obtaining an actual value of the selected parameter; comparing the actual value to the profile for the selected parameter; as well as An operating condition of the shredder is determined based on a comparison between the actual value and the profile of the selected parameter. 2 . The method of claim 1 , further comprising determining, based on the comparison, that the shredder is operating under one of a normal condition, a sub-normal condition, and an abnormal condition. 3 . The method of claim 1 , further comprising determining that the shredder is operating under a subnormal condition when the actual value is within the predetermined range.

4. The method of claim 1, wherein the selected parameter is selected from the group consisting of: vibration, temperature, and current, torque, and electrical power of a motor of the shredder.

5. The method according to claim 4, wherein the actual value of the selected parameter is obtained by a sensor, preferably a vibration sensor or a temperature sensor, or is obtained by calculation based on one or more other parameters. The method according to claim 1 , wherein the profile is obtained based on experimental data, statistics or machine learning.

7. The method of claim 1, wherein the shredder is disposed downstream of a forming device and is configured to cut waste material removed from the forming device.

8. The method of claim 7, wherein the profile is specific to a process performed by the forming apparatus or a product formed by the forming apparatus.

9. The method of claim 7, further comprising adjusting an operating parameter of the forming apparatus when the actual value is within the predetermined range.

10. The method of claim 1, further comprising determining, by a controller, that the shredder is operating under an abnormal condition when the actual value is outside the predetermined range. The method of claim 1 , wherein the predetermined range has limits that coincide with limits of the tolerance.

12. A system comprising: A shredder, which is disposed downstream of the forming device and is configured to cut the waste generated in the forming device into small pieces, the shredder comprising: at least one of a sensor and a parameter determination module for obtaining an actual value of a parameter selected to be monitored; a memory configured to store a configuration file of selected parameters corresponding to a plurality of parts to be formed in the forming apparatus; and A comparison module is configured to compare the actual value with the configuration file to determine the operating condition of the shredder.

13. The system of claim 12, wherein the configuration files each include a nominal value for the selected parameter, a tolerance for the nominal value, and a predetermined range of deviation of the selected parameter from the tolerance for the nominal value.

14. The system of claim 13, wherein the comparison module is configured to determine that the shredder is operating in a subnormal condition when the actual value is within the predetermined range, and to determine that the shredder is operating in an abnormal condition when the actual value deviates from the tolerance of the nominal value and is outside the predetermined range.

15. The system of claim 12, wherein the comparison module is in communication with a controller of the forming device such that the controller of the forming device is configured to adjust operating parameters of the forming device based on the operating conditions of the shredder.

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