Impact Press Calibration via Eccentric Shaft Angle Control
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Solution Overview
Problem
The existing methods for calibrating impact presses are complex and imprecise, particularly in adjusting the length of the connecting rod, which is necessary for achieving the prescribed crimping force and height, especially when the crimping position is not at the bottom dead center of the eccentric shaft.
Innovation Solution
A method that uses a motor-driven eccentric shaft to position the press ram with a measuring transducer, recording and storing the rotation angle to achieve the desired pressing force at any predetermined height, eliminating the need for separate connecting rod adjustments and allowing for precise calibration and operation with new crimping tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the length of the connecting rod is adjusted to achieve the prescribed crimping force and height, then the crimping quality is improved, but the adjustment process becomes complex and time-consuming
Solution Approach 1:
The patent replaces the mechanical adjustment system (connecting rod length adjustment with adjusting disks) with an electronic control system. A measured value sensor detects the actual crimping force and height, a comparator compares these values with target values, and a control unit automatically adjusts the eccentric shaft rotation angle to achieve precise crimping parameters without manual mechanical adjustment.
Solution Approach 2:
The system performs self-calibration and self-adjustment through the feedback loop. The measured value sensor continuously monitors the crimping process, and the control unit automatically corrects deviations from target values by adjusting the eccentric shaft, eliminating the need for manual intervention and complex adjustment procedures.
2Measurement precision
If the connecting rod length is precisely adjusted to match manufacturing tolerances, then the crimping force accuracy is improved, but the calibration time and operational complexity increase
Solution Approach 1:
The patent replaces time-consuming manual measurement and adjustment procedures with an electronic measurement and control system. The measured value sensor immediately detects crimping parameters, and the control unit rapidly computes and applies corrections, reducing calibration time from minutes or hours to seconds while improving accuracy.
Solution Approach 2:
The system implements a closed-loop feedback mechanism where the measured value sensor continuously monitors crimping force and height, compares actual values with target values through the comparator, and automatically adjusts the eccentric shaft rotation angle. This real-time feedback eliminates iterative manual adjustment and significantly reduces calibration time.
3Ease of operation
If the crimping position is assigned to the bottom dead center of the eccentric shaft, then the mechanical setup is simplified, but the ability to achieve precise pressing force at arbitrary heights is limited
Solution Approach 1:
The patent transforms the static crimping position assignment (fixed at bottom dead center) into a dynamic system where the crimping position can be arbitrarily adjusted by changing the eccentric shaft rotation angle. The control unit calculates the optimal rotation angle based on desired crimping force and height requirements, allowing flexible adaptation to different crimping tools and specifications.
Solution Approach 2:
The system changes the operating parameter from a fixed mechanical position (bottom dead center) to a variable rotational angle of the eccentric shaft. By adjusting the rotation angle as a controllable parameter, the system can achieve precise pressing forces at arbitrary heights while maintaining ease of operation through electronic control.
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 enables precise calibration and operation of impact presses, improving crimp quality by storing relevant values such as pressing force and sensor height, reducing operational complexity and wear, and enhancing durability through robust transducer design.
Implementation Method 1
the measured value sensor containing a force sensor (5)
Implementation Method 2
the measured value sensor containing a signal-generating height measuring device (6)
Implementation Method 3
the impact press has a signal-generating angle of rotation sensor (7) for detecting relative rotations of the eccentric shaft (2)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The method involves moving a press bear (3) vertically by a motor driven eccentric shaft (2), with which a readings recorder (4) is inserted in an impact press (1). The press bear is shifted by the eccentric shaft in the direction of the readings recorder, till the desired press capacity is obtained by a level specified arbitrarily and the attainder angle of rotation of the eccentric shaft is stored to be detected upon recalling. An independent claim is also included for a device for calibration of an impact press.