Slack Control in Plastic Working Systems for Coil Feeding
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Solution Overview
Problem
Conventional plastic working systems face issues with coil material flapping and erroneous feeding due to intermittent feeding mechanisms, especially when multiple press devices are arranged in series, leading to reduced productivity and accuracy.
Innovation Solution
A plastic working system that includes a first slack watching means to monitor and control the slack in the coil material from a preceding plastic working device, converting intermittent feeding to continuous feeding and adjusting the feeding speed using sensors and a feed adjusting device to stabilize the coil material supply to succeeding devices, thereby minimizing flapping and ensuring stable feeding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If an intermittently feeding mechanism is used to supply coil material to press devices, then the press operation can be executed with precise timing, but the coil material vibrates and flaps causing erroneous feeding
Solution Approach 1:
A feed roller acts as an intermediary device between the coil material and the press device. The feed roller continuously feeds the coil material while a loop controller maintains an appropriate loop size, mediating between the intermittent press operation and the continuous material flow to prevent flapping and erroneous feeding
Solution Approach 2:
The feed roller operates continuously to supply coil material to the press device, eliminating the intermittent feeding action that causes flapping. The continuous feeding action maintains stable material tension and position, preventing vibration and erroneous feeding while the press device operates intermittently
2Productivity
If multiple press devices are arranged in series to enhance productivity, then the production capacity increases, but the flapping of workpiece between devices causes erroneous feeding
Solution Approach 1:
Feed rollers are installed as intermediary devices between multiple press devices to continuously supply workpiece material. These intermediaries maintain appropriate loop sizes and prevent flapping, ensuring stable feeding to each press device while allowing synchronous operation at high speed
Solution Approach 2:
A loop controller with position sensors provides feedback control to the feed rollers. The sensors detect the loop size of coil material, and this feedback signal controls the servo motor speed to maintain an appropriate loop, preventing flapping and erroneous feeding between press devices
3Productivity
If the operation speed is increased to enhance productivity, then the production efficiency improves, but the flapping of coil material becomes more severe
Solution Approach 1:
The feed roller operates continuously at high speed to supply coil material, eliminating intermittent feeding actions that cause flapping. This continuous action maintains stable material tension even at high operation speeds, preventing vibration and damage
Solution Approach 2:
The loop controller provides real-time feedback control by detecting loop size with position sensors and adjusting servo motor speed accordingly. This feedback mechanism maintains appropriate loop size even during high-speed operation, preventing flapping and ensuring material stability
Data Source
AI summary
A plurality of press devices 2 are arranged in a plastic working system. The plastic working system includes: a loop correction sensor 13 for watching a slack of a coil material C intermittently delivered from a preceding first press device 2a; and a second slack watching means 19 for watching a slack of the coil material C generated at the time of sending the coil material C to a succeeding second press device 2b. According to the slack generated by intermittent feeding of the coil material C sent from the first press device 2a, intermittent feeding is converted to continuous feeding by the feeding means 15. At the same time, the continuous feeding speed is subjected to speed increasing/decreasing control. On the other hand, by the second slack watching means 19, a slack of the coil material C is watched at the time of feeding the coil material C to the second press device 2b and the preceding first press device 2a is subjected to speed increasing/decreasing control.