Bending Machine Control for Accurate Sheet Radius Correction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Modern bending machines face challenges in achieving precise bending of large sheets due to deviations in material properties, leading to inaccuracies in bending radius, which are difficult to correct economically, especially when the desired radius is too small, and often require multi-pass methods to minimize waste.
Innovation Solution
A control method and configured bending machine that uses a controller with a digital signal processor and stored data sets to adjust roller positions based on material properties and previous bending operations, applying correction factors to achieve the desired curvature in as few steps as possible, utilizing a multi-pass approach with iterative adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If material properties are assumed to be known and constant for bending calculations, then bending machine settings can be determined in advance, but actual bending radius deviates from desired radius due to material property variations
Solution Approach 1:
The system measures the actual bending radius after a bending operation and uses this measurement as feedback to calculate corrected bending machine settings for subsequent operations. The controller adjusts settings based on the difference between desired and actual bending radii, creating a closed-loop control system that compensates for material property variations.
Solution Approach 2:
The system performs a preliminary bending operation to measure the actual bending radius before determining the final bending settings. This preliminary action provides information about actual material properties, which is then used to calculate corrected settings that will achieve the desired bending radius in subsequent operations.
2Manufacturing precision
If multi-pass bending method is used to correct bending radius deviations, then bending precision can be improved, but production time increases and productivity decreases
Solution Approach 1:
A preliminary bending operation is performed to measure actual material behavior and determine corrected settings. This single preliminary pass replaces multiple corrective passes by providing information that allows calculation of optimal settings for achieving the desired bending radius in subsequent operations.
Solution Approach 2:
The system uses feedback from measuring the actual bending radius to calculate corrected settings, eliminating the need for iterative multi-pass correction. The feedback mechanism allows the system to determine the appropriate settings in advance, reducing the number of bending passes required.
3Ease of manufacture
If bending machine settings are calculated based on theoretical material properties, then setup is simplified, but bending accuracy deteriorates due to deviations from actual material properties
Solution Approach 1:
The system maintains simplicity in setup by using theoretical material properties for initial calculations, then improves accuracy by incorporating feedback from actual bending measurements. The controller automatically adjusts settings based on measured bending radii, combining simple setup with high precision.
Solution Approach 2:
The system changes the bending machine parameters (roller positions, forces) based on feedback from actual bending operations. Instead of changing material properties or complex setup procedures, the system dynamically adjusts operational parameters to compensate for material variations.
4Manufacturing precision
If corrective bending operations are performed to adjust bending radius, then bending precision can be improved, but material waste increases when correction is not economically feasible
Solution Approach 1:
A preliminary bending operation is performed to measure actual material behavior and calculate corrected settings before the final bending operation. This preliminary action prevents material waste by ensuring that subsequent bending operations will achieve the desired radius without requiring costly corrective measures or scrapping the sheet.
Data Source
AI summary
A method and a correspondingly configured bending machine are described, wherein a setting of the bending machine is first calculated on the basis of a mathematical model and subsequently corrected on the basis of stored data sets on previous bending operations and their correction values.