Die Cushion Wrinkle Detection Using Slide-Pad Position Deviation
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Solution Overview
Problem
Current methods for detecting wrinkles in materials formed by press machines are limited in their ability to consecutively monitor wrinkle generation over time, leading to ineffective automatic control of die cushion force, increased scrap production, and potential die breakage due to lack of timely intervention.
Innovation Solution
A wrinkle generation detection device that includes a slide position detector, a cushion pad position detector, and a computing unit to calculate deviations between the slide and cushion pad positions continuously from the start to the end of material forming, allowing for real-time detection and automatic adjustment of die cushion force to prevent wrinkles and emergency stop of the press machine if necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional wrinkle detection methods are used, then wrinkle detection is possible, but continuous monitoring during the entire forming process cannot be achieved
Solution Approach 1:
The patent implements continuous monitoring of the cushion pad position throughout the entire forming process using a position detector. The control unit continuously calculates the difference between the cushion pad position and slide position, enabling uninterrupted detection of wrinkle generation from start to end of forming, thus achieving continuous useful action in wrinkle detection.
2Reliability
If manual adjustment of die cushion force is used, then wrinkle prevention can be attempted, but extensive trial-and-error time and scrap production occur
Solution Approach 1:
The patent establishes a feedback control loop where the control unit continuously monitors the cushion pad position and compares it with the slide position. When wrinkles are detected through position deviation, the system automatically adjusts the die cushion force in real-time, eliminating manual trial-and-error processes and reducing both adjustment time and scrap production.
Solution Approach 2:
The control system automatically detects wrinkles and adjusts die cushion force without requiring manual intervention. The system serves itself by using the detected position information to autonomously optimize the forming process, reducing dependency on operator experience and minimizing scrap production.
3Reliability
If die cushion force is increased to prevent wrinkles, then wrinkle generation is reduced, but die breakage risk increases due to excessive force
Solution Approach 1:
The patent dynamically adjusts the die cushion force based on real-time wrinkle detection. Instead of applying excessive force continuously, the system optimizes the cushion force level by modifying control parameters when wrinkles are detected, thereby preventing both wrinkle generation and die breakage through adaptive, condition-based control.
Solution Approach 2:
The control unit changes control parameters of the die cushion force based on detected wrinkle conditions. This allows precise adjustment of force application, increasing cushion force only when and where needed to prevent wrinkles, while maintaining safe force levels otherwise, thus avoiding die breakage.
Data Source
AI summary
In a press machine having a die cushion device which supports a cushion pad and which generates a die cushion force when a slide of the press machine is lowered, the wrinkle generation detection device includes: a slide position detector which detects a height position of the slide; a cushion pad position detector which detects a height position of the cushion pad; and a computing unit which consecutively calculates a deviation between the height position of the slide detected by the slide position detector and the height position of the cushion pad detected by the cushion pad position detector, during a time period from the start of forming of a material by the slide lowering to the end of the forming, wherein a wrinkle generated in the material is detected based on an increase of the deviation consecutively calculated by the computing unit.