Die Cushion Pressure Control With Adaptive Slide Waiting
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Solution Overview
Problem
The pressure control system in machine tools with die cushions often experiences delays, leading to inadequate pressure application, which can result in defects like wrinkles and cracks during processing, due to insufficient responsiveness.
Innovation Solution
A control apparatus that includes a slide position control unit, pressure command generation unit, pressure detection unit, die cushion speed control unit, and command reach determination unit, which sets a waiting period when the actual pressure does not meet the pressure threshold, ensuring sufficient pressure is applied before transitioning to the next operation pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the pressure control system operates without a waiting period, then productivity is improved by continuous operation, but manufacturing precision deteriorates due to insufficient pressure application causing defects
Solution Approach 1:
The control apparatus introduces a waiting period before the slide moves to the next position, allowing the pressure control system to reach the target pressure in advance. This preliminary action ensures that sufficient pressure is applied to the object to be processed before the next operation begins, preventing defects while maintaining efficient production cycles
2Manufacturing precision
If the waiting period is extended to ensure pressure reach, then manufacturing precision is improved, but productivity deteriorates due to increased cycle time
Solution Approach 1:
The control apparatus dynamically adjusts the waiting period duration based on real-time pressure feedback. The waiting period is set to the minimum necessary time for the pressure control system to reach the target pressure, rather than using a fixed extended duration. This dynamic adjustment ensures processing quality while minimizing the impact on productivity
3Productivity
If the pressure control system responds quickly, then productivity is improved, but manufacturing precision deteriorates due to pressure instability causing defects
Solution Approach 1:
The control apparatus incorporates a pressure detection unit that provides real-time feedback on the actual pressure applied to the object to be processed. This feedback mechanism allows the control system to monitor pressure stability and adjust the waiting period accordingly, ensuring that pressure reaches a stable target value before the next operation begins, thereby preventing defects while maintaining efficient production
Data Source
AI summary
A control apparatus of a machine tool includes: a slide position control unit configured to control a slide according to operation patterns; a pressure command generation unit configured to generate a pressure command for a die cushion according to the operation patterns; a pressure detection unit configured to detect an actual pressure of the die cushion; a die cushion speed control unit configured to control the die cushion, based on an error between the pressure command and the actual pressure; and a command reach determination unit configured to determine whether or not the error is greater than a pressure threshold, wherein the slide position control unit sets, based on a result of the determination by the command reach determination unit, a waiting period between the operation pattern at the time of the determination and the next operation pattern, wherein the slide is kept at its position during the waiting period.