Crimping Machine In-Process Measurement for Quality Control
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Solution Overview
Problem
Prior crimping machines require separate verifying measurements post-processing, leading to delays, inaccuracies, and production of defective work pieces due to strain and deformation issues, necessitating integration of measurement within the crimping process for real-time monitoring and quick corrections.
Innovation Solution
Incorporating sensors and a control system within the crimping machine to monitor pressure and position during and after crimping, using a single measuring device for the cylinder actuator, and reducing pressure to minimize strain, allowing for immediate feedback and adjustments in the crimping process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate verifying measurements are performed after crimping, then quality control is achieved, but production time increases and defects are detected too late
Solution Approach 1:
The patent combines the verifying measurement function with the crimping machine itself by integrating a measuring device that can measure the work piece while it is still held in the crimping machine. This merging of measurement and crimping functions eliminates the need for separate post-processing measurement steps, thereby reducing production time while maintaining quality control.
Solution Approach 2:
The patent performs the verifying measurement before the work piece is removed from the crimping machine, while the crimping force is still applied. This preliminary measurement allows for immediate detection of defects and potential readjustments before production continues, preventing defective work pieces from being produced in batches.
2Productivity
If measurements are taken during crimping with pressure applied, then real-time monitoring is achieved, but measurement accuracy decreases due to strain and deformation
Solution Approach 1:
The patent employs periodic measurement cycles during the crimping process. The measuring device takes measurements at specific intervals or at key stages of the crimping cycle, allowing for real-time monitoring while accounting for the dynamic nature of the crimping process and the changing strain conditions on the work piece.
Data Source
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AI summary
A crimping system, a control circuit for a crimping machine, and a method to be applied in them, in which: a work piece (15) is subjected to a first force effect by an actuator (5) that is controlled by the pressure of pressurized medium, wherein said force effect is proportional to said pressure and causes a desired deformation in the work piece (15); a follow-up measurement is taken, whose measurement result is proportional either to the dimension of the work piece (15) or said pressure; the work piece (15) is subjected to a second force effect but by applying a reduced pressure which is lower than the pressure that contributes to said deformation; and a verifying measurement is taken, whose measurement result is proportional to the dimension of the work piece (15), when said reduced pressure controls said actuator (5) and the work piece (15) is still in the crimping machine (1).