Die Cushion Control Device Pressure Deviation Prediction
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Solution Overview
Problem
Existing die cushion control methods require trial and error to determine a constant for compensating pressure drops, leading to inefficient pressure control and potential defects in press-formed products due to over or undercompensation.
Innovation Solution
A die cushion control device that predicts pressure deviations based on translational acceleration and control parameters, generating a correction pressure command to adjust the pressure command, ensuring accurate pressure control without requiring user-adjusted constants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a constant is used to multiply acceleration for pressure compensation, then pressure drop can be compensated, but determining the appropriate constant requires time-consuming trial and error
Solution Approach 1:
The system uses feedback from the actual pressure detector and slide acceleration to dynamically calculate the pressure deviation. The feedback control unit continuously adjusts the pressure command value based on the calculated deviation, eliminating the need for manual trial-and-error determination of compensation constants while maintaining accurate pressure control.
Solution Approach 2:
The system performs self-adjustment by automatically calculating the pressure deviation using the measured acceleration and control parameters. The compensation is generated autonomously through the deviation calculation unit and feedback control unit, which use the system's own operational data to correct pressure drops without external intervention or manual tuning.
2Reliability
If the constant for acceleration multiplication is too large, then pressure drop is overcompensated causing pressure to exceed target value, but if the constant is too small, then pressure drop is undercompensated
Solution Approach 1:
The system transitions from using a fixed compensation constant to a dynamic compensation approach. The pressure deviation is calculated in real-time based on the actual acceleration and control parameters at each moment, allowing the compensation amount to adapt dynamically to changing operating conditions. This prevents both overcompensation and undercompensation by continuously adjusting to the actual system state.
Solution Approach 2:
The system changes the parameter used for compensation from a static constant to a dynamically calculated value based on acceleration and control parameters. By using the relationship between acceleration, control parameters, and pressure deviation, the system automatically adjusts the compensation magnitude to match the actual pressure drop, eliminating the need to select from fixed constant values.
3Reliability
If trial and error method is used to determine the compensation constant, then appropriate compensation can be achieved, but the process becomes inefficient and time-consuming
Solution Approach 1:
The system replaces the manual mechanical process of trial-and-error adjustment with an automated computational system. The deviation calculation unit and feedback control unit use mathematical relationships between acceleration, control parameters, and pressure to automatically determine the correct compensation amount, eliminating the need for iterative manual adjustment and significantly improving setup efficiency.
Solution Approach 2:
The system introduces an intermediary calculation process that uses slide acceleration and control parameters as intermediate variables to determine the pressure deviation. This intermediary approach provides a direct computational path from measurable quantities to the required compensation value, replacing the indirect trial-and-error method and enabling immediate accurate compensation.
Data Source
AI summary
A die cushion control device for controlling a die cushion mechanism includes: a pressure command generation unit that outputs a first pressure command on pressure or force to be generated between the die cushion mechanism and a slide; a deviation prediction unit that predicts a pressure deviation that is the difference between the pressure or the force in the first pressure command and a detected pressure caused when the die cushion mechanism is controlled according to the first pressure command, and outputs the predicted pressure deviation as a correction pressure command; a pressure command correction unit that corrects the first pressure command with the correction pressure command to calculate a second pressure command; and a pressure control unit that calculates a speed command to cause the detected pressure to follow the second pressure command, and outputs the speed command to a speed control unit.