Die Cushion Force Distribution for Complex Drawn Parts
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Solution Overview
Problem
Existing die cushion force setting methods for die cushion apparatuses are cumbersome and imprecise, especially when dealing with complex-shaped parts, as they require manual adjustment of multiple driving shafts, leading to discontinuous die cushion force distribution and difficulty in applying strong or weak forces to specific regions.
Innovation Solution
A die cushion force setting apparatus that uses input devices to enter a total die cushion force and additional information, such as center-of-force position or imaginary plane inclination, to numerically compute and set die cushion forces on multiple driving shafts, allowing for continuous and precise force distribution across the cushion pad.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual setting of die cushion force on each driving shaft is performed, then individual force adjustment is possible, but the operation becomes troublesome and time-consuming when there are a large number of driving shafts
Solution Approach 1:
The patent uses a model cushion pad that replicates the geometric shape and driving shaft arrangement of the actual cushion pad. By placing weight pieces on this model, the operator creates a simplified copy representation of the force distribution, which is then automatically translated into control signals for the actual multiple driving shafts, eliminating manual individual setting
Solution Approach 2:
The model cushion pad serves as an intermediary device between the operator's intent and the actual force application system. Weight pieces placed on the model create a physical representation of desired force distribution, which is then converted by the control device into appropriate control signals for each driving shaft, simplifying the operation
2Manufacturing precision
If manual setting of die cushion force is performed, then some adjustment is possible, but it is difficult to apply strong or weak force to specifically shaped regions and achieve smooth force distribution
Solution Approach 1:
The patent enables different die cushion forces to be applied to different regions of the cushion pad by placing weight pieces at specific locations on the model cushion pad. The control device translates the positional information of weight pieces into localized force adjustments, allowing strong or weak forces to be applied to specifically shaped regions according to the geometric model
Solution Approach 2:
The model cushion pad copies the geometric shape and structural characteristics of the actual cushion pad, including the arrangement of driving shafts. This copying allows the operator to visually and physically configure the desired force distribution pattern on the model, which is then accurately reproduced on the actual system with smooth continuous distribution
3Extent of automation
If all die cushion forces are entered manually, then complete control is possible, but the operation becomes extremely troublesome compared to entering only one force value
Solution Approach 1:
The model cushion pad creates a simplified physical copy of the force distribution problem. Instead of manually entering multiple force values, the operator only needs to place weight pieces on the model, which automatically generates the corresponding control signals for all driving shafts through the control device, significantly reducing operational complexity
Solution Approach 2:
The system performs self-service by automatically calculating and generating the control signals for all driving shafts based on the simple input of weight piece positions on the model cushion pad. The control device autonomously translates the physical configuration into the appropriate force distribution without requiring manual intervention for each individual shaft
Data Source
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AI summary
The die cushion force setting apparatus according to an aspect of the present invention allows die cushion forces (component forces) acting on plural driving shafts (4a) to be set easily, makes it easy to apply strong or weak die cushion forces to a complex-shaped drawn part in a plane of a cushion pad (2), and provides a smooth die cushion force distribution. An operator manually enters (step S18A) a total die cushion force, axial component force of a left front hydraulic cylinder (4LF), and center-of-force position by operating an input device (A1). Based on the information entered via the input device (A1), the numerical computing device B1 calculates (step S18B) axial component forces of three hydraulic cylinders (4LB, 4RF, 4RB) through numerical computations. The one axial component force thus entered and three axial component forces thus computed numerically are set (step S18C) as the axial component forces of four hydraulic cylinders (4LF, 4LB, 4RF, 4RB).