Dual Distance Measuring System for Tool Holder Position Verification
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Solution Overview
Problem
Existing forming apparatuses face challenges in achieving safety-oriented shutdown with minimal technical outlay while maintaining workpiece handling efficiency, particularly in ensuring accurate position control of the tool holder relative to the machine bed to prevent injuries.
Innovation Solution
The implementation of a dual distance measuring system where the first system provides real-time position signals for rapid control and the second system provides more accurate, albeit delayed, signals to confirm the accuracy of the first system's signals, allowing for safe shutdown by comparing the two within a preset tolerance range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a single distance measuring system is used for real-time position control, then the response speed is fast, but the reliability of position data is insufficient for safety-critical shutdown decisions
Solution Approach 1:
The distance measuring function is segmented into two independent systems: a first distance measuring system for real-time position control with fast response, and a second distance measuring system for safety verification with higher reliability. This segmentation allows each system to be optimized for its specific purpose while working together to solve the contradiction between speed and reliability.
2Reliability
If a second distance measuring system is added for verification, then the reliability of shutdown decisions is improved, but the device complexity and cost increase
Solution Approach 1:
The patent merges the functions of both distance measuring systems into a unified monitoring device that automatically compares position data from both systems. This integration reduces the need for separate verification mechanisms and simplifies the overall system architecture while maintaining the reliability benefits of dual measurement.
Solution Approach 2:
The monitoring device implements a feedback mechanism where position data from the first and second distance measuring systems is continuously compared, and any discrepancies trigger automatic shutdown decisions. This feedback loop ensures high reliability without requiring complex manual verification procedures.
3Speed
If the second distance measuring system operates in real-time, then the verification speed is fast, but the cost and complexity increase significantly
Solution Approach 1:
The system dynamically adjusts the operational mode of the second distance measuring system based on the operational phase. During normal operation, the first system provides real-time control while the second system provides periodic verification. During critical phases or when discrepancies are detected, the verification frequency increases. This dynamic operation maintains safety while reducing overall system complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach ensures reliable and efficient shutdown of the drive unit with minimal additional components and costs, reducing the risk of operator injury by verifying the accuracy of position data in real-time operations.
Implementation Method 1
a monitoring device (7) designed for monitoring movements of the tool holder (4) and for provision of a shutdown signal to a disconnector unit (17) upstream of the drive unit (16), if a presettable monitoring event occurs
Implementation Method 2
a first distance measuring system (12) and a second distance measuring system (13), each designed to emit position signals to determine a position of the tool holder (4) relative to the machine bed (2)
Data Source
AI summary
A forming apparatus comprises: a machine bed; a tool holder mounted movably relative to the machine bed; a drive unit connected to the tool holder; a disconnector unit; a machine control for operating the drive unit; and a monitoring device to monitor movements of the tool holder and to activate the disconnector unit. The monitoring unit includes two distance measuring systems that respectively generate first and second position signals at different rates for determining a position of the tool holder relative to the machine bed. At least one radiation beam detector is deactivated in response to a different between the first and second position signals undershooting a predetermined value.