Bending Material Shape Checking for Springback Error Correction
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Solution Overview
Problem
The automobile industry faces challenges in accurately predicting and correcting springback in bending materials, leading to dimensional errors and shape deviations, which require manual and resource-intensive post-process corrections.
Innovation Solution
A shape checking device for bending materials, comprising a material fixing unit, a distance measuring unit with multiple distance measuring devices, and a shape inferring unit, which measures and calculates distortion to ensure accurate shape measurement and correction, integrated into a forming machine for continuous shape checking and forming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual measurement operations are used to check dimensions after forming, then measurement can be performed, but time, space, and personnel resources are consumed
Solution Approach 1:
The patent replaces manual mechanical measurement operations with an automated optical measurement system using a camera and image processing. The measurement unit captures images of the formed product and automatically calculates dimensional data, eliminating the need for manual measurement while maintaining measurement accuracy and reducing time consumption.
Solution Approach 2:
The measurement system performs self-service by automatically capturing images, processing them through image recognition algorithms, and generating measurement results without human intervention. The system independently completes the entire measurement workflow from image acquisition to dimensional analysis.
2Productivity
If springback correction is performed based on sample data, then forming can be completed, but dimensional errors occur due to physical property deviation between coils
Solution Approach 1:
The patent implements a feedback mechanism where the actual shape of each formed product is measured and compared with the target shape. The springback correction values are continuously updated based on measurement results from previous products, allowing the system to adapt to variations in material properties between different coils and improve precision while maintaining productivity.
Solution Approach 2:
The system performs preliminary springback correction based on sample data before actual production, then uses feedback from measurements to refine correction values. This preliminary action allows forming to proceed efficiently while subsequent feedback ensures dimensional accuracy compensates for material variations.
3Measurement precision
If multiple distance measuring devices are used to measure the same surface at different positions, then measurement accuracy is improved, but device complexity increases
Solution Approach 1:
The patent measures the same surface at multiple positions along the bending direction (different locations on the formed product) rather than using multiple devices at the same position. This dimensional approach allows comprehensive shape measurement using a single measuring device, improving accuracy without increasing device complexity.
Solution Approach 2:
The single distance measuring device is designed to measure multiple different positions on the formed product by moving along the bending direction. This multi-functional capability allows one device to perform the work of multiple devices, maintaining measurement precision while avoiding increased system complexity.
Data Source
AI summary
The present invention provides a shape checking device for a bending material including: a material fixing unit including a support member in which a first surface of a material including a first surface and a second surface, bent from the first surface is seated, and a pressing member configured to press the first surface of the material; and a distance measuring unit, and measuring a distance to the second surface, wherein the distance measuring unit includes a first distance measuring device for measuring a distance to the second surface, and a second distance measuring device for measuring a distance to a second surface, which is the same as the second surface on which a distance thereof is measured by the first distance measuring device, in a position, spaced apart from the first distance measuring device in a first direction, different from a bending forming direction of a material.