Metal Press Crosshead Alignment Using Optical Feedback Guides
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Solution Overview
Problem
Existing methods for monitoring and correcting the central alignment of slidably guided components in extrusion presses, such as running bars and pickup holders, are indirect and difficult to automate, leading to challenges in maintaining high dimensional accuracy and repeatability due to factors like tilting or asymmetrical thermal expansion.
Innovation Solution
A method involving continuous measurement of central alignment using two reference points transverse to the press's longitudinal axis, with automatically adjustable guide elements, allowing for precise monitoring and correction of the component's position relative to the main axis using image-processing sensors and laser triangulation, enabling automatic adjustment and improved repeatability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If indirect measurement methods are used to detect alignment deviations, then measurement capability is provided, but automation of monitoring and correction becomes difficult
Solution Approach 1:
The patent replaces indirect mechanical measurement methods with direct optical image processing. Instead of using mechanical sensors that require complex interpretation, the system uses cameras to capture images of reference markings on the crosshead and traveling beam, then processes these images computationally to directly obtain alignment deviation data, enabling straightforward automation.
Solution Approach 2:
The patent creates optical copies (images) of the physical components' positions through reference markings and camera imaging. By capturing images of the reference markings and processing them to extract position information, the system creates a digital representation of the physical alignment state, which can be easily automated and processed without complex mechanical measurement interpretation.
2Reliability
If manual correction methods are used, then alignment adjustments can be made, but operational efficiency and repeatability decrease
Solution Approach 1:
The patent implements a closed-loop feedback system where the image processing continuously monitors the actual positions of the crosshead and traveling beam, compares them with target positions, and automatically generates correction signals to the guide elements. This automated feedback loop ensures consistent alignment correction while improving operational efficiency by eliminating manual intervention.
Solution Approach 2:
The system enables the press to automatically monitor and correct its own alignment without external manual intervention. The image processing system continuously tracks the positions, calculates deviations, and the control system automatically adjusts the guide elements, allowing the machine to self-correct alignment issues and maintain optimal operation autonomously.
3Productivity
If automated guide elements are implemented, then correction speed improves, but system complexity increases
Solution Approach 1:
The patent employs guide elements that serve multiple functions: they provide mechanical guidance for the crosshead and traveling beam, act as adjustment mechanisms for alignment correction, and work in conjunction with the image processing system for automated control. This multi-functionality reduces the need for separate dedicated components, thereby managing system complexity while maintaining automated correction capabilities.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution allows for precise monitoring and correction of component alignment with sub-millimeter accuracy, reducing wear and maintaining tight tolerances in pressed components, enhancing the operational reliability and accuracy of extrusion processes.
Implementation Method 1
with automatically adjustable guide elements, allowing for precise monitoring and correction of the component's position relative to the main axis using image-processing sensors and laser triangulation
Data Source
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AI summary
The invention relates to a method for monitoring the position and changing the position of at least one component, more particularly a running bar (3), slidingly guided within a press frame (2) between abutments of the press frame (2). The method comprises continuously measuring a central alignment of the component within the press frame (2) and correcting the alignment of the component within the press frame (2) in accordance with the acquired measurement result by means of preferably automatically adjustable guide elements (10) of the sliding guides (6) of the press. The central alignment of the slidingly guided component within the press frame (2) is measured by the sensing of the location of at least one, preferably two reference points (7) of the slidingly guided component preferably in a plane extending perpendicularly to the longitudinal center axis (4) of the press. The invention also relates to a press having automatically adjustable guide elements (10) and means for controlling the guide elements (10) in accordance with the measured position of the component.