Automated Bending Angle Measurement System
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Solution Overview
Problem
Current bending machines for metal sheet plates and profiles require manual angle measurement and rely on error-prone formulas, leading to inefficiencies and time losses due to material variability and human error in achieving the desired bending angle.
Innovation Solution
An automated bending angle measurement system using dual laser sensors and a control device that continuously measures and adjusts the bending angle, ensuring accuracy by recalculating and repositioning the bending elements until the target angle is achieved within +/-1 mm precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual angle measurement devices are used, then the bending angle can be measured, but the process requires substantial time loss and human intervention
Solution Approach 1:
The patent replaces manual mechanical angle measurement devices with an automated sensor-based measurement system. Distance sensors (laser or ultrasonic) automatically measure the bending angle by detecting the position of the workpiece, eliminating the need for manual intervention and significantly reducing measurement time while maintaining precision.
Solution Approach 2:
The measurement system performs self-service by automatically measuring the bending angle without human intervention. The sensors continuously monitor the bending process and provide real-time feedback to the control unit, enabling the system to self-regulate and eliminate the time loss associated with manual measurement operations.
2Reliability
If separate bending for every material is realized and recorded, then material variability is accounted for, but the process becomes difficult and time-consuming
Solution Approach 1:
The patent implements a feedback mechanism where distance sensors continuously measure the actual bending angle and transmit this data to a control unit. The control unit compares the measured angle with the target angle and automatically adjusts the bending process in real-time, eliminating the need for separate manual adjustments for different materials and significantly improving productivity while maintaining reliability.
Solution Approach 2:
The system performs preliminary action by pre-programming bending parameters for different materials in a database. When a new material is processed, the system automatically retrieves the appropriate parameters and adjusts the bending process accordingly, eliminating the need for manual setup and recording for each material type.
3Manufacturing precision
If formulas based on machine geometry are used, then bending calculations can be performed, but error risk occurs due to human factors
Solution Approach 1:
The patent replaces manual calculation methods based on geometric formulas with an automated sensor-based measurement and control system. Distance sensors directly measure the bending angle in real-time, and the control unit automatically processes the data to determine when the target angle is achieved, eliminating human calculation errors and significantly improving both precision and reliability.
4Extent of automation
If automated sensor-based measurement is implemented, then bending angle can be measured automatically, but device complexity increases
Solution Approach 1:
The patent employs universal distance sensors that can measure both the bending angle and the radius of curvature. The same sensor system serves multiple functions: measuring the workpiece position, calculating the bending angle, and providing feedback for process control. This multi-functionality reduces the need for additional specialized components, thereby limiting the increase in device complexity while achieving high automation.
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 enables precise and efficient automatic measurement and attainment of the desired bending angle, reducing time loss and error by continuously monitoring and adjusting the bending process until the target is reached.
Implementation Method 1
measuring the distance between the bending part and itself by means of laser rays
Implementation Method 2
the laser ray...reflects back from the surface...provided in the opposite and the related sensor generates coordinates
Data Source
Figure 1
Figure 2
AI summary
The present invention relates to a bending angle measurement system for use in cylinder and profile bending machines and which determines the angle, formed during bending of the bending part (20), by means distance measurement device and which checks said angle and which provides said angle to reach the desired angle. The sensor (10) measures the distance between said bending part (20) and itself by means of laser and transfers measurement data to the control device (70). The control device (70) transforms said measurement data, transferred by the sensor (10), into angle value, and checks whether the bending part (20) has reached the bending angle targeted by the user, and checks the forward-backward movement of the bending part (20) between the upper holder element (41 ) and the lower holder element (42). The control device (70) moreover adjusts the position of the bending element (50) in order to adjust the bending angle of the bending part (20).