Electromechanical Drive Torque Control for Shaping Tool Braking
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Solution Overview
Problem
Existing forming machine technologies, particularly those using hydraulic press drives, face challenges in achieving precise and reproducible forming steps, with inadequate braking torque and efficiency, leading to prolonged braking times and potential inaccuracies in workpiece transformation.
Innovation Solution
The method involves an electrical drive source generating drive torque before a movement phase of the forming tool, with the braking device counteracting the drive moment. The braking device is controlled to transition between a braking position and a released position, allowing for intermittent work movement of the forming tool, thereby enhancing control and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hydraulic press drive is used with conventional braking devices, then the machine safety is ensured, but the braking torque is too low and the braking time is too long
Solution Approach 1:
The patent replaces the conventional hydraulic press drive with an electromechanical drive system comprising an electric motor, gear unit, and spindle. This substitution enables precise control of the forming tool's movement and allows for rapid braking through electrical control, eliminating the slow mechanical braking of hydraulic systems while maintaining safety through controlled deceleration.
Solution Approach 2:
The patent changes the fundamental operating parameters from hydraulic pressure control to electrical torque and speed control. The electric motor provides variable torque output, and the gear unit with spindle converts rotational motion to linear motion with precise positioning. This parameter change enables both high-speed operation and rapid braking by simply adjusting electrical commands.
2Productivity
If the forming tool operates continuously, then the productivity is maintained, but the precision and reproducibility of forming steps deteriorates
Solution Approach 1:
The patent implements periodic intermittent operation of the forming tool through the electromechanical drive system. The electric motor can rapidly accelerate and decelerate the forming tool, enabling repeated cycles of movement and stopping. This periodic action allows multiple forming steps to be performed with consistent precision while maintaining high overall productivity through rapid cycle times.
Solution Approach 2:
The patent incorporates a control unit that monitors and controls the electromechanical drive system. This feedback mechanism ensures that each forming step is executed with precise positioning and force control, maintaining manufacturing precision across multiple cycles. The control unit can detect position and adjust the motor output to achieve repeatable forming results.
3Measurement precision
If the braking device is activated frequently, then the control precision is improved, but the response time of the braking process increases
Solution Approach 1:
The patent replaces mechanical braking mechanisms with electrical control of the motor. The electric motor can be commanded to stop by simply cutting power or applying reverse torque, eliminating the mechanical friction and wear of conventional brakes. This substitution reduces braking response time to milliseconds while maintaining precise control through the control unit.
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 immediate and precise control over the forming tool's movement, improving the efficiency and accuracy of workpiece formation. The braking system's enhanced control function allows for quicker response times and more defined power application, reducing processing latency and increasing overall system reliability.
Implementation Method 1
the electrical drive source generates a drive torque while the braking device is in the braking position, so that the braking torque of the braking device counteracts the drive torque of the electrical drive source
Implementation Method 2
a braking device (5) operable between a released position and a braking position for braking and/or blocking the working movement (32) of the forming tool (28)
Data Source
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AI summary
The invention relates to a method for shaping a workpiece (27), comprising a shaping machine (20). The shaping machine (20) comprises at least one electromechanical drive (1) with an electric drive source (2), at least one shaping tool (28), the working movement (32) of which is produced by the electromechanical drive (1), and at least one brake device (5), which can be actuated between a release position and a braking position, for braking and/or blocking the working movement (32) of the shaping tool (28). The invention is characterized in that prior to a movement phase (33) of the shaping tool (28), the electric drive source (2) generates a drive torque (M) while the brake device (5) is in the braking position such that the braking torque (B) of the brake device (5) counteracts the drive torque (M) of the electric drive source (2), and the beginning of the movement phase (33) of the shaping tool (28) is initiated by converting the brake device (5) into the release position and/or into a position with a reduced braking torque and/or the working movement (32) of the shaping tool (28) is carried out intermittently during a shaping step.