Die Cushion Velocity Control for Press Noise Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional control devices for die cushion mechanisms in press machines lack the ability to optimize velocity commands for the die cushion and slide, leading to excessive noise and mold damage due to improper velocity alignment, while attempting to suppress noise results in insufficient workpiece processing.
Innovation Solution
A control device that uses servo motors to form velocity commands for the slide and die cushion, incorporating a velocity relation calculation based on the rate of force increase between the slide and die cushion after collision, allowing for the determination of optimal velocity commands that balance noise reduction and effective workpiece processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the velocity command for the die cushion mechanism is decreased to suppress collision noise, then the noise is reduced, but the pressure acting on the workpiece decreases and the workpiece is not worked to a sufficient degree
Solution Approach 1:
The control device dynamically adjusts the velocity command for the die cushion mechanism based on the actual collision velocity between the slide and die cushion. By making the velocity command variable rather than fixed, the system can optimize performance in real-time - using higher velocities when needed for effective workpiece processing and lower velocities when collision noise becomes excessive, thus resolving the contradiction between noise suppression and processing quality
Solution Approach 2:
The control device calculates the actual collision velocity and uses this feedback information to adjust the velocity command for the die cushion mechanism. This closed-loop control allows the system to respond to actual operating conditions and optimize the balance between suppressing collision noise and maintaining adequate workpiece processing pressure
2Object-affected harmful factors
If the relative velocity between the die cushion and slide is decreased to suppress noise, then the noise is reduced, but the impact on molds decreases causing insufficient workpiece processing
Solution Approach 1:
The system dynamically determines the velocity command based on calculated collision velocity, allowing the impact force on molds to be optimized for each operating condition rather than using a fixed low velocity that would always suppress noise but never provide sufficient processing force
Solution Approach 2:
The control device changes the velocity parameter of the die cushion mechanism based on the calculated collision velocity and determined velocity command, allowing optimization of both noise suppression and adequate mold impact force for effective workpiece processing
Data Source
AI summary
A control device (10) for a die cushion mechanism that produces a force for a slide (24) in a press machine, comprising slide velocity command-forming means (61) for forming a velocity command for the slide (24), die cushion velocity command-forming means (62) for forming a velocity command for said die cushion (20), and velocity relation calculation means (65) for calculating a velocity relation between the velocity of the slide and the velocity of the die cushion based on a rate of increase (dF) in the force produced between the slide and the die cushion immediately after the collision of the slide with the die cushion. The cushion velocity command-forming means forms the velocity command for the die cushion based upon the slide velocity command formed by the slide velocity command-forming means and upon the velocity relation calculated by the velocity relation-calculation means. This makes it possible to form an optimum velocity command for the slide and/or the die cushion.