Bending Angle Compensation for Time-Dependent Springback
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Solution Overview
Problem
Existing bending machines struggle to accurately maintain the desired bending angle of metallic workpieces due to material springback, which can change over time, especially when there is a delay between bending and subsequent machining.
Innovation Solution
A bending machine equipped with a controller that calculates an adapted bending angle based on time-dependent springback data, allowing the workpiece to be overbent to compensate for springback during storage, ensuring the correct angle is achieved at the time of subsequent machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the workpiece is bent to the exact desired bending angle, then the bending operation is precise initially, but the bending angle deviates over time due to springback during storage
Solution Approach 1:
The controller calculates and applies a preliminary compensation angle during the bending operation based on predicted springback. The bending machine bends the workpiece beyond the desired angle by the calculated springback amount, so that after springback occurs during storage, the workpiece achieves the exact desired bending angle at the time of subsequent machining.
Solution Approach 2:
The system applies an opposite action to counteract the anticipated springback effect. By calculating the expected springback magnitude and direction, the controller applies an equal and opposite overbending angle during the initial bending operation, effectively neutralizing the future springback deviation and maintaining bending angle stability over time.
2Stability of the object's composition
If the bending machine compensates for springback by overbending, then the bending angle stability is improved, but the device complexity increases due to calculation and control requirements
Solution Approach 1:
The controller receives feedback information about the desired bending angle and storage time, calculates the appropriate springback compensation, and adjusts the bending operation accordingly. This closed-loop control ensures that the bending angle stability is maintained while managing the complexity through systematic calculation and control algorithms.
Solution Approach 2:
The system changes the bending angle parameter dynamically based on storage time and material properties. By adjusting the bending angle beyond the desired value according to calculated springback parameters, the system achieves bending angle stability without requiring complex mechanical modifications, only computational adjustments to the bending parameter.
3Reliability
If the bending operation accounts for storage time springback, then the reliability of subsequent machining is improved, but the manufacturing time increases due to additional calculations and adjustments
Solution Approach 1:
The springback compensation calculation is performed in advance during the bending operation planning phase, using predicted storage time and material properties. This preliminary calculation integrates the compensation into the initial bending operation, eliminating the need for time-consuming adjustments after storage and ensuring machining reliability without significant time penalty.
Solution Approach 2:
The system replaces manual trial-and-error bending adjustments with automated computational calculations. The controller automatically computes the required overbending angle based on storage time and material data, substituting mechanical adjustment processes with efficient digital calculations that reduce overall manufacturing time while improving reliability.
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
This approach ensures precise bending angles during subsequent machining by accounting for both immediate and future springback, enabling tailored machining processes like automatic welding and reducing errors.
Implementation Method 1
the inherent springback of the material during or immediately after the bending operation can also be compensated
Implementation Method 2
The bending machine according to the invention takes into account that the bending angle reached after the bending operation, for example, depending on the bending speed and material, undergoes an additional provision during storage of the part after the completed bending operation
Data Source
AI summary
The invention relates to a bending machine (100) configured to bend a metallic workpiece (200), having a controller (130) configured to control a bending operation, wherein the controller (130) has at least one interface (340) configured to obtain information about a time-dependent springback of the workpiece (200) to be bent and to obtain a time indication of a subsequent further machining of the workpiece (200) to be bent, wherein the controller (130) is configured to calculate an adapted bending angle (α) based on the springback and the time indication, and wherein the bending machine (100) is configured to bend the bending operation beyond a bending angle (β) to be bent up to the adapted bending angle (α). Due to the adapted bending angle, the workpiece (300) has the correct bending angle (β) to be bent at the time of subsequent further machining.