Bending Tool Exchange Alignment Using Stocker Stopper Correction
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Solution Overview
Problem
The existing bending systems face challenges in correcting tool misalignment in stockers positioned at exchange positions, particularly during horizontal reversal operations, which disrupts the automatic tool exchange process.
Innovation Solution
The proposed bending system incorporates a control device that controls a pair of tool exchange units and moving actuators to position tools correctly within the stockers, ensuring alignment by moving the tool exchange units until the tools abut on stoppers corresponding to regular arrangement positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If the stocker moving mechanism performs horizontal reversal operation to position the stocker at the exchange position, then the tool exchange automation is improved, but tool misalignment from regular arrangement position occurs
Solution Approach 1:
The pressing member (ball plunger) is activated before the stocker reaches the exchange position to push the tool back to its regular arrangement position. This preliminary action prevents misalignment from occurring in the first place, rather than correcting it after the fact.
Solution Approach 2:
The system uses detection means (sensors) to monitor tool position and alignment status. When misalignment is detected or anticipated during the reversal operation, the control device activates the pressing member to correct the position, creating a closed-loop feedback system that maintains precision despite automated movement.
2Stability of the object's composition
If the tool is pressed by a pressing member such as a ball plunger to prevent misalignment, then tool alignment stability is improved, but the system cannot grasp and correct misalignment that occurs during bending operations
Solution Approach 1:
The detection means continuously monitors tool alignment status during bending operations. When misalignment occurs despite the pressing member's preventive action, the system detects it and triggers the correction routine, creating a reliable feedback loop that ensures both prevention and correction capabilities.
Solution Approach 2:
The system automatically detects and corrects its own misalignment problems without external intervention. The detection means identifies the issue and the control device activates the appropriate correction mechanism, allowing the system to self-correct during operation.
3Manufacturing precision
If the tool exchange unit moves to correct misalignment by abutting on stopper, then tool alignment precision is improved, but the operation time increases
Solution Approach 1:
The pressing member corrects misalignment during the normal tool exchange sequence before the tool is fully positioned, rather than requiring a separate correction operation. This integrates the alignment correction into the existing workflow, minimizing additional time expenditure.
Solution Approach 2:
The correction operations are integrated into the continuous tool exchange and bending workflow. The pressing member acts during natural pauses in the cycle, and the tool exchange unit makes minor adjustments without stopping the overall production flow, maintaining continuous useful action.
Data Source
AI summary
In a case where a vacant space exists on only one side in a holder area of a stocker positioned at an exchange position, a first upper tool exchange unit is first moved in the left-right direction, and located in the vicinity of the vacant space. Next, the first upper tool exchange unit is moved forward and thereafter moved to the left, so that a tool retention member of the first upper tool exchange unit is brought into contact with one side surface of a tool. Then, under the contact state, the first upper tool exchange unit is moved to the right until the other side surface of the tool abuts on a stopper.