An intelligent trial punching die and its optimization method

Abstract

The present invention relates to the field of thin-walled profile stamping dies, and specifically to an intelligent trial stamping die and an optimization method thereof. The intelligent trial stamping die includes a male die, a female die module, a plurality of drive modules, a sensor array, a signal acquisition and analysis module, and an intelligent control module. The male die has a convex molding surface, and the top wall of the female die module can adaptively change from a flat surface to a concave curved surface following the downward pressing movement of the male die; the signal acquisition and analysis module determines the deviation from the preset target state based on the physical state information transmitted by the sensor array, and the intelligent control module generates compensation instructions based on the deviation to regulate the movement of the plurality of drive modules in real time to adaptively correct the stamping process. The embodiments of the present invention overcome the influence of material batch differences and rebound effects through real-time perception and closed-loop fine-tuning, replace the tedious manual trial die and parameter adjustment process, and the batch stamping program can be optimized according to the compensation amount during the trial stamping, thereby improving production efficiency.

Description

Technical Field

[0001] The present invention relates to the field of thin-wall profile stamping dies, and in particular to an intelligent trial stamping die and an optimization method thereof. Background Art

[0002] In ladder manufacturing, to improve stability, the outer frame columns are typically designed with a parallel upper portion and outward-flaring lower portion. This structure requires a long metal profile (usually a thin-walled channel steel) to be bent into an obtuse-angled broken line through a molding process.

[0003] Traditional stamping dies for mass production usually include a male die that matches the outer surface contour of the workpiece and a female die module for supporting the inner surface of the workpiece. In order to reduce the cost of the die, the female die module is usually not a single female die that matches the inner surface contour of the workpiece, but is composed of a central female die located at the bending center and two side female dies located on both sides. During stamping, the male die is pressed down, and at the same time, the central female die and the side female die are driven by their respective drive modules (such as servo motors, hydraulic cylinders) and move in coordination according to a pre-set, fixed motion program, thereby bending the workpiece into shape.

[0004] However, due to the subtle and inevitable differences in the thickness, hardness, ductility and other mechanical properties of metal profiles between different production batches, when the same motion program is used to stamp these different workpieces, it will lead to quality problems such as different bending angles, distorted cross-sections, local excessive thinning or wrinkling in the final products.

[0005] The mother mold module is universal and adjustable, and its structure is not specifically optimized for each specification of profile and each ladder frame with different bending angles and bending radius. Therefore, when replacing each batch of new materials, experienced technicians must conduct repeated mold trials and parameter adjustments. This process is highly dependent on personal experience, which not only consumes a lot of time but also generates a large amount of waste, seriously affecting the overall efficiency of the production line and equipment utilization. Summary of the Invention

[0006] The purpose of the present invention is to provide an intelligent trial punching die and its optimization method, aiming to solve the problems of low automation level, low production efficiency, product quality being greatly affected by differences in raw material batches, and the debugging process being cumbersome and relying on manual experience in traditional stamping methods.

[0007] In order to solve the above technical problems, the present invention specifically provides the following technical solutions:

[0008] An intelligent trial punching die, comprising:

[0009] a male die having a convex forming surface that matches the target curved outer surface contour of the workpiece;

[0010] A female mold assembly, the top wall of which can adaptively transform from a flat surface to a concave curved surface following the downward pressing movement of the male mold, thereby cooperating with the male mold to bend the workpiece into shape;

[0011] A plurality of drive modules, used for driving the male mold and the female mold module to move in coordination;

[0012] A sensor array is arranged on the contact surface between the mother mold assembly and the workpiece, and is used to monitor the physical state information of the workpiece during the stamping process in real time;

[0013] a signal acquisition and analysis module, electrically connected to the sensor array, for analyzing the physical state information and determining its deviation from a preset target state;

[0014] The intelligent control module generates compensation instructions according to the deviation and regulates the movement of the plurality of drive modules in real time to adaptively correct the stamping process.

[0015] Furthermore, the master mold assembly includes:

[0016] A central female mold, disposed directly below the male mold, for supporting the bending center of the workpiece;

[0017] At least one side master mold is arranged on the side of the central master mold along the length direction of the workpiece, and is used to support the wing arms formed after the workpiece is bent. The end of the side master mold close to the central master mold can swing around a horizontal rotation axis located at the other end of the side master mold, and the horizontal rotation axis is perpendicular to the length direction of the workpiece.

[0018] Furthermore, the driving module includes:

[0019] A first Z-axis linear drive module, whose actuator is fixedly connected to the male mold and is used to drive the male mold to move vertically along the Z-axis direction;

[0020] A second Z-axis linear drive module, whose actuator is fixedly connected to the central female mold and is used to drive the central female mold to move vertically along the Z-axis following the male mold;

[0021] The third Z-axis linear drive module has an actuator that is slidably connected to one end of the side master mold close to the center master mold, and is used to drive the end of the side master mold close to the center master mold to move vertically along the Z-axis direction so that it can swing downward following the descent of the center master mold.

[0022] Furthermore, the driving module further includes:

[0023] The X-axis linear drive module has an actuator fixedly connected to the horizontal rotation axis of the side mother mold and the third Z-axis linear drive module, and is used to drive the side mother mold and the third Z-axis linear drive module to move along the length direction of the workpiece.

[0024] Furthermore, the second Z-axis linear drive module and the third Z-axis linear drive module both include:

[0025] A servo drive unit for performing forming movements with large strokes;

[0026] An electromagnetic drive unit is coaxially arranged in series with the servo drive unit for performing high-frequency, small-displacement correction movements.

[0027] Furthermore, the servo drive unit is a servo motor linear module, and the electromagnetic drive unit is a piezoelectric ceramic driver or a voice coil motor.

[0028] Furthermore, the sensor array is arranged at: the top center support area of ​​the central master mold and / or the top support surface of the side master mold, for monitoring the stress state or stress distribution of the workpiece.

[0029] An optimization method for an intelligent trial punching die comprises the following steps:

[0030] Step 1: Test, monitoring, collection and calculation:

[0031] A servo drive unit in a plurality of drive modules of the mold is driven to perform a forming motion according to an initial motion program. During the forming motion, a sensor array arranged on the surface of the mold is used to collect physical state information of the workpiece in real time, and the collected physical state information is compared with a preset target state to determine a deviation between the two.

[0032] Step 2: Dynamic compensation:

[0033] If it is determined that there is a deviation, a compensation instruction is generated, and the driving module is driven to perform a correction movement to dynamically reduce or eliminate the deviation.

[0034] Furthermore, the optimization method further includes the following steps:

[0035] Step 3: Program optimization:

[0036] The compensation instructions that successfully eliminate the deviation in step 2 are recorded, and the initial motion program is optimized accordingly to form an optimized motion program suitable for the current batch of workpieces, and then steps 1 and 2 are repeated until the physical state information of the workpiece during the bending process meets the preset target state.

[0037] Furthermore, the optimization method further includes the following steps:

[0038] Step 4: Optimize batch production process:

[0039] The optimized motion program finally obtained is output to one or more batch stamping dies including the male die, the female die assembly and the driving die assembly to guide the production.

[0040] The beneficial effects of the present invention are:

[0041] The embodiments of the present invention effectively overcome the impact of material batch differences and rebound effects through real-time perception and closed-loop fine-tuning, allowing the mold's adaptive capabilities to replace the tedious manual mold trial and parameter adjustment process, thereby improving production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] To more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for the embodiments or the description of the prior art. Obviously, the drawings described below are merely exemplary, and those skilled in the art can derive other implementation drawings based on the provided drawings without inventive effort.

[0043] Figure 1 A perspective view of an embodiment of the present invention;

[0044] Figure 2 A front view of an embodiment of the present invention;

[0045] Figure 3 A top view of an embodiment of the present invention;

[0046] Figure 4 for Figure 3 Cross-sectional view in the AA direction;

[0047] The numbers in the figure represent the following:

[0048] 1-Male mold; 11-Protruding molding surface; 2-Center mother mold; 3-Side mother mold; 31-Horizontal rotation axis; 4-Workpiece; 41-Bending center; 42-Wing arm; 51-First Z-axis linear drive module; 52-Second Z-axis linear drive module; 55-Servo drive unit; 56-Electromagnetic drive unit; 53-X-axis linear drive module; 54-Third Z-axis linear drive module. DETAILED DESCRIPTION

[0049] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0050] In order to overcome the defects existing in the background technology, the present invention provides an intelligent trial punching die and an optimization method thereof, aiming to realize closed-loop adaptive control of the metal profile bending forming process, thereby ensuring that high-precision and high-consistency products can still be obtained when facing fluctuations in material properties of different batches.

[0051] The staff can refer to the "compensation parameters" used by the intelligent trial punching mold during the trial punching process to adjust the "initial parameters" of the batch stamping mold, modify the initial height difference and initial horizontal distance difference between the center mother mold 2 and the side mother mold 3, as well as the pressing speed of the male mold 1, the descending speed of the center mother mold 2, the rotation speed of the side mother mold 3 during the stamping process, etc., so as to quickly adjust the stamping program of each batch of new materials and achieve high-efficiency production.

[0052] The intelligent trial punching die provided by the present invention is described in detail below.

[0053] The core inventive concept of the intelligent test punching die of the present invention lies in the integration of an advanced sensing system, a control system, and an innovative dual-layer drive architecture. Its overall structure and functions can be divided into the following key parts:

[0054] 1. The main structure of the mold

[0055] The intelligent trial punching die comprises a male die 1 and a female die module matched therewith.

[0056] The bottom wall of the male die 1 has a convex molding surface 11 that matches the outer surface contour of the target bent workpiece 4. The male die 1 is driven by a first Z-axis linear drive module 51 (usually a hydraulic cylinder) to perform the main vertical downward pressing motion.

[0057] The female mold assembly is located below the male mold 1 and is used to provide dynamic and continuous support to the inner surface of the workpiece 4 during the stamping process.

[0058] The master mold set includes:

[0059] The central mother mold 2 is located directly below the apex of the curved path, and its top surface is used to support the curved center 41 area of ​​the workpiece 4.

[0060] The two side mother molds 3 are symmetrically arranged on both sides of the central mother mold 2, and the top surfaces thereof are used to support the two wing arms 42 formed after the workpiece 4 is bent.

[0061] The master mold module driving system is the key to achieving dynamic support, including a driving module for driving the central master mold 2 and driving modules for driving the two side master molds 3 respectively.

[0062] In order to simultaneously meet the requirements of large-scale molding movement and micron-level precision correction, the intelligent trial punching mold of the present invention adopts a double-layer hybrid drive architecture of "servo macro drive + electromagnetic micro correction" in the key mother mold drive part.

[0063] Drive of the center mother mold 2: The center mother mold 2 is driven by a second Z-axis linear drive module 52. This module is not a single drive unit, but rather consists of a servo motor linear module and an electromagnetic drive (such as a piezoelectric ceramic drive or voice coil motor) connected in series. The servo motor linear module is responsible for executing the large-stroke, high-thrust macro-down motion to follow the male mold 1 to complete the main molding trajectory.

[0064] The electromagnetic driver connected in series with it can respond to electrical signals within microseconds and produce high-frequency, micron-level telescopic displacement, which enables the central mother mold 2 to perform ultra-fine real-time height fine-tuning based on macroscopic movement.

[0065] Drive of side master mold 3:

[0066] Each side mother mold 3 is driven by an XR driving module to achieve movement toward or away from each other in the horizontal direction (X axis) and swing around a horizontal rotation axis 31 (R axis).

[0067] The XR drive module decouples complex compound motions through an ingenious mechanical structure:

[0068] An X-axis linear drive module 53 (usually a servo screw slide) is responsible for the overall horizontal translation, mainly used to adapt to the change of the bending radius of the workpiece 4 and adjust the horizontal distance between the center mother mold 2 and the side mother mold 3.

[0069] A third Z-axis linear drive module 54 drives the side mother mold 3 to swing around the R axis through the action of a lever.

[0070] The XR driving module is used to adjust the rotation angle of each side master mold 3 and its distance from the central master mold 2 in real time, thereby adjusting the curvature and radius of the curved surface formed by the overall top wall of the master mold module.

[0071] In the present invention, the third Z-axis linear drive module 54 also adopts a double-layer hybrid drive design, that is, it is composed of a servo motor linear module and an electromagnetic driver connected in series.

[0072] The servo motor is responsible for driving the side master mold 3 to complete a large-angle macro-swing to match the main bending curve, while the electromagnetic drive is used to perform real-time, high-frequency micro-correction of the swing angle.

[0073] 2. Closed-loop adaptive control system (not shown)

[0074] The control system includes:

[0075] The bending center sensor array is set in the central support area on the top of the central mother mold 2. This is the apex of the force on the workpiece 4 and is the key to judging whether the main punch pressure and bending degree are appropriate.

[0076] The wing wall sensor array is arranged on the top supporting surfaces of the two side mother molds 3, which support the two wing arms 42 of the workpiece 4. The pressure distribution thereof directly reflects the flow, extension and wrinkling tendency of the material.

[0077] The signal acquisition and analysis module receives all the raw data from the sensor array through a high-speed data acquisition card.

[0078] The intelligent control module includes a processor and a controller.

[0079] The processor is used to perform real-time in-depth analysis of the raw data (for example, a comparison algorithm based on an ideal mechanical model, or a prediction algorithm based on machine learning), which can instantly determine the deviation between the actual stress state and the ideal forming state, and predict the trend and amplitude of rebound.

[0080] The controller receives the deviation results from the analysis module, generates compensation instructions accordingly, and sends them to each drive module respectively.

[0081] The overall working process of the test punching is described as follows.

[0082] Conventional stamping procedure: When stamping starts, the male mold 1 is pressed down, and the servo motor linear module in the female mold module drives the central female mold 2 and the side female mold 3 to perform a large range of following and swinging motions according to a basic motion program, forming the main forming trajectory.

[0083] Real-time perception and analysis: At every moment of movement, the sensor array senses the actual force conditions of the workpiece 4 and transmits the data stream to the signal acquisition and analysis module in real time. The signal acquisition and analysis module sends the signal to the processor, which compares the actual data with the ideal data model and calculates the deviation. For example, if the center point pressure exceeds the threshold, it indicates that the material is too hard, or if a sudden drop in pressure is detected somewhere on the flank, it indicates that local instability has occurred.

[0084] Microscopic real-time correction: The controller receives the deviation signal sent by the processor, calculates the compensation required for the moving distance of the second Z-axis linear drive module 52, the X-axis linear drive module 53 and the third Z-axis linear drive module 54, and sends a high-frequency drive instruction to the series-connected electromagnetic driver.

[0085] If the center pressure is too high, the electromagnetic driver driving the center mother mold 2 will retract quickly at the micron level to soften the support and prevent the workpiece 4 from being crushed.

[0086] If the supporting force of the side wings is uneven, the electromagnetic driver driving the side mother mold 3 will make fine adjustments, instantly changing the supporting angle of the side mother mold 3, re-establishing a uniform supporting force field, and suppressing the occurrence of distortion.

[0087] This "macro-servo motion + micro-electromagnetic correction" process is continuously cycled throughout the entire stamping cycle. Ultimately, the controller calculates the ideal parameters (initial parameters + compensation parameters) for the batch stamping process and applies them to the batch stamping process.

[0088] The beneficial effects of the present invention are:

[0089] Through real-time perception and closed-loop fine-tuning, the impact of material batch differences and rebound effects is effectively overcome, making the size and angle of each product highly consistent and the yield rate greatly improved.

[0090] The mold's adaptive capability replaces the tedious manual mold trial and parameter adjustment process. When faced with a new batch of materials, the system can automatically learn and optimize the best control strategy within one or two stampings, greatly improving production efficiency and equipment utilization.

[0091] The innovative double-layer hybrid drive system perfectly combines the large stroke and high thrust of the servo with the high speed and high precision of the electromagnetic drive, achieving unprecedented fine control over the stamping process and suppressing minor defects that are difficult to avoid in traditional processes.

[0092] All data accumulated by the system during the adaptive adjustment process (including material properties, stress changes, compensation instructions, etc.) can be recorded and analyzed, providing a valuable data foundation for process optimization, quality traceability and predictive maintenance.

[0093] The above embodiments are merely exemplary embodiments of the present invention and are not intended to limit the present invention. The scope of protection of the present invention is defined by the claims. Those skilled in the art may make various modifications or equivalent substitutions to the present invention within the essence and scope of protection of the present invention. Such modifications or equivalent substitutions should also be regarded as embodiments of the present invention falling within the scope of protection of the present invention.

Claims

1. An intelligent trial punching die, characterized in that: include: a male die having a convex forming surface that matches the target curved outer surface contour of the workpiece; a female mold assembly, disposed directly below the male mold, wherein the top wall of the female mold assembly can adaptively transform from a flat surface to a concave curved surface following the downward pressing movement of the male mold, thereby cooperating with the male mold to bend the workpiece into shape, the female mold assembly comprising a central female mold assembly and at least one side female mold assembly, wherein the side female mold assembly is disposed beside the central female mold assembly along the length direction of the workpiece; A plurality of drive modules for driving the male mold, the central mother mold, and the side mother molds to perform coordinated motion, wherein the drive modules for driving the central mother mold and the side mother molds each include a servo drive unit for performing large-stroke molding motion, and an electromagnetic drive unit coaxially arranged in series with the servo drive unit for performing high-frequency, micron-level displacement correction motion; a sensor array, arranged in the top central support area of ​​the central master mold and the top support surface of the side master mold, for real-time monitoring of physical state information of the workpiece, wherein the physical state information is the stress state of the workpiece during the stamping process; a signal acquisition and analysis module, electrically connected to the sensor array, for analyzing the physical state information and determining its deviation from a preset target state; The intelligent control module generates compensation instructions according to the deviation and regulates the movement of the plurality of drive modules in real time to adaptively correct the stamping process.

2. The intelligent trial punching die according to claim 1, characterized in that: One end of the side master mold close to the central master mold can swing around a horizontal rotation axis located at the other end of the side master mold, and the horizontal rotation axis is perpendicular to the length direction of the workpiece.

3. The intelligent trial punching die according to claim 2, characterized in that: The plurality of driving modules include: A first Z-axis linear drive module, whose actuator is fixedly connected to the male mold and is used to drive the male mold to move vertically along the Z-axis direction; A second Z-axis linear drive module, whose actuator is fixedly connected to the central female mold and is used to drive the central female mold to move vertically along the Z-axis following the male mold; The third Z-axis linear drive module has an actuator that is slidably connected to one end of the side master mold close to the center master mold, and is used to drive the end of the side master mold close to the center master mold to move vertically along the Z-axis direction so that it can swing downward following the descent of the center master mold.

4. The intelligent trial punching die according to claim 3, characterized in that: The plurality of driving modules further include: The X-axis linear drive module has an actuator fixedly connected to the horizontal rotation axis of the side mother mold and the third Z-axis linear drive module, and is used to drive the side mother mold and the third Z-axis linear drive module to move along the length direction of the workpiece.

5. The intelligent trial punching die according to claim 1, characterized in that: The servo drive unit is a servo motor linear module, and the electromagnetic drive unit is a piezoelectric ceramic driver or a voice coil motor.

6. An optimization method for an intelligent trial punching die according to any one of claims 1 to 5, characterized in that: The following steps are involved: Step 1: Test, monitoring, collection and calculation: A servo drive unit in a plurality of drive modules of the mold is driven to perform a forming motion according to an initial motion program. During the forming motion, a sensor array arranged on the surface of the mold is used to collect physical state information of the workpiece in real time, and the collected physical state information is compared with a preset target state to determine a deviation between the two. Step 2: Dynamic compensation: If it is determined that there is a deviation, a compensation instruction is generated, and the driving module is driven to perform a correction movement to dynamically reduce or eliminate the deviation.

7. The optimization method according to claim 6, characterized in that: The following steps are also included: Step 3: Program optimization: The compensation instructions that successfully eliminate the deviation in step 2 are recorded, and the initial motion program is optimized accordingly to form an optimized motion program suitable for the current batch of workpieces, and then steps 1 and 2 are repeated until the physical state information of the workpiece during the bending process meets the preset target state.

8. The optimization method according to claim 7, characterized in that: The following steps are also included: Step 4: Optimize batch production process: The optimized motion program finally obtained is output to one or more batch stamping dies including the male die, the female die assembly and the driving die assembly to guide the production.

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