Active Crowning Press Control Without Dissipative Valves
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Solution Overview
Problem
Existing bending presses with crowning systems suffer from energy waste, operational inefficiency, and reduced lifespan due to the need for continuous operation and the presence of dissipative elements like valves and solenoid valves, which cause oil heating and performance loss.
Innovation Solution
A bending press with an active crowning system that uses a variable speed pump motor and deformation transducers to activate the crowning system only when needed, eliminating dissipative elements and using a central control unit to manage oil flow dynamically, ensuring precise deformation control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the crowning system is kept operational continuously, then it is ready when necessary, but energy is wasted and the system components deteriorate faster
Solution Approach 1:
The crowning system is activated periodically only when needed during sheet bending operations rather than running continuously. The control unit activates the crowning cylinders during bending and deactivates them during idle periods, eliminating unnecessary energy consumption while maintaining operational readiness when required
2Ease of operation
If valves and solenoid valves are used in the crowning system, then oil flow can be controlled, but energy is dissipated and oil heating occurs
Solution Approach 1:
The patent removes dissipative elements (valves and solenoid valves) from the crowning system. Instead of using traditional valve-based control, the system uses a pump that directly controls oil flow to the crowning cylinders, eliminating energy dissipation and heat generation associated with valve operation
3Loss of energy
If the crowning system is activated only when needed, then energy waste is reduced, but the system must be rapidly activated when required
Solution Approach 1:
The control unit is configured to activate the crowning system in advance or immediately when bending operations are detected or initiated. By using sensors to detect sheet presence and bending requirements, the system prepares and activates crowning at the optimal moment, ensuring rapid response while maintaining energy efficiency during idle periods
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system reduces energy waste, extends the useful life of the crowning system by minimizing oil heating and performance loss, and optimizes power usage by activating only during processing, thus enhancing operational efficiency.
Implementation Method 1
a variable speed pump motor (32)
Implementation Method 2
at least one crowning cylinder (18, 20, 22) connected to a pressurized oil feeding apparatus (24)
Implementation Method 3
at least one position or deformation transducer (28) positioned on the lower beam (16)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A bending press (12) with active crowning system comprises an upper beam (14) and a lower beam (16). The lower beam (16) is provided with at least one crowning cylinder (18, 20, 22) connected to a pressurized oil feeding apparatus (24). The bending press further comprises at least one position or deformation transducer (26) arranged on the upper beam (14), at least one position or deformation transducer (28) arranged on the lower beam (16), and a central control unit (30) to which the position or deformation transducers (26, 28) and the oil feeding apparatus (24) are operatively connected. The pressurized oil feeding apparatus (24) is driven by a variable speed pump motor (32), based on the position or deformation measured at the at least one position or deformation transducer (26) arranged on the upper beam (14), and at least one position or deformation transducer (28) arranged on the lower beam (16).