Bending Tool Layout Using Change Frequency to Cut Setup Time
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Solution Overview
Problem
Existing methods for optimizing the setup of bending tools in bending machines are inefficient, particularly with frequent changes, leading to prolonged setup times and increased wear, which affects productivity and maintenance costs.
Innovation Solution
A method and system that determine the optimal positioning of bending tools based on change frequency indicators, allowing for selective placement and fixation of bending punches and dies relative to tool holders, and utilizing an automated bending tool changing device to minimize setup time and tool changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If bending tools are frequently changed to adapt to different bending models, then adaptability is improved, but setup time increases and productivity decreases
Solution Approach 1:
The system performs preliminary analysis of the bending order batch to determine the optimal set of bending tools that can handle multiple bending models. By pre-determining the tool set before production, the system avoids frequent tool changes during operation, thus reducing setup time while maintaining adaptability across different bending models.
Solution Approach 2:
The system identifies a universal set of bending tools that can be used across multiple bending models and orders. By selecting tools with multi-functional capability that can serve various bending operations, the system reduces the need for frequent tool changes, thereby decreasing setup time while maintaining high adaptability.
2Adaptability or versatility
If bending tools are repositioned frequently to optimize for different bending models, then adaptability is improved, but tool wear increases and maintenance costs rise
Solution Approach 1:
The system determines the optimal bending tool positions in advance by analyzing the bending order batch. By pre-calculating the tool layout that can accommodate multiple bending models, the system minimizes the need for frequent repositioning during production, thereby reducing tool wear and maintenance costs while maintaining adaptability.
Solution Approach 2:
The system selects a universal tool configuration that can serve multiple bending models without requiring frequent repositioning. By choosing tools and positions that have broad applicability across different bending orders, the system reduces mechanical stress and wear on individual tools, extending their service life.
3Adaptability or versatility
If manual determination of tool layout is used, then flexibility is maintained, but setup time increases and operator experience dependency arises
Solution Approach 1:
The system automatically determines the optimal bending tool set and positions by analyzing the bending order batch itself. This self-service capability eliminates the need for manual operator intervention in tool selection and positioning, thereby increasing setup efficiency and productivity while maintaining the flexibility to adapt to different bending models through automated decision-making.
Solution Approach 2:
The system uses feedback from the bending order batch data to automatically optimize tool selection and positioning. By continuously analyzing the requirements of multiple bending models and adjusting the tool configuration accordingly, the system achieves both high flexibility and efficient setup without relying on operator experience.
Data Source
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AI summary
The invention relates to a method and a system for optimising the configuration of bending tools (9, 10) of a bending machine (1), which bending tools (9, 10) are formed from a plurality of bending punches (14) in serial succession and from a plurality of bending dies (11) in serial succession, which functionally cooperate with the bending punches (14). Data of at least one bending model, which provides the basis for a workpiece (3) that is to be made, or data of a plurality of bending jobs from a bending job stack, which jobs are to be carried out sequentially, is entered into a computing unit (25). In view of at least one of the bending models to be implemented or in view of the at least one bending job stack to be completed, the computing unit (25) determines a characteristic change frequency value (30) for at least some individual bending tools (9, 10). Taking into account the respective characteristic change frequency values (30) for the bending tools (9, 10), positions of the individual bending tools (9, 10) relative to their tool holders (12, 15) are determined or proposed by the computing unit (25), and the bending tools (9, 10) are positioned in the bending machine (1) taking into account the characteristic change frequency values (30) for the bending tools (9, 10).