Foil Pressure Sensor for Stamping Tool Makeready
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Solution Overview
Problem
Existing flatbed sheet punching and embossing machines face challenges in achieving uniform punching pressure distribution, leading to inefficiencies and high setup times due to the need for iterative adjustments and manual trimming of tools, which reduces machine productivity.
Innovation Solution
The method involves using a flat, foil-shaped pressure distribution sensor to measure and calculate the makeready requirement distribution, allowing for precise adjustment and visualization of trimming needs, thereby streamlining tool preparation and surface correction processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual trimming of tools is performed to achieve uniform punching pressure, then punching precision is improved, but setup time increases significantly
Solution Approach 1:
The patent applies preliminary action by measuring the pressure distribution and calculating the makeready requirements before actual tool preparation. The system determines the complete trimming distribution in advance using pressure sensors and computational algorithms, allowing operators to prepare tools efficiently based on pre-calculated guidance rather than through iterative trial-and-adjustment processes.
Solution Approach 2:
The patent implements feedback by using pressure distribution sensors to measure actual pressure patterns during punching operations. This measured data is fed back into the system to calculate accurate makeready requirements, creating a closed-loop control system that enables precise tool adjustment based on real performance data rather than estimation or repeated manual testing.
2Manufacturing precision
If iterative adjustments are made to achieve uniform pressure distribution, then punching quality is improved, but machine productivity decreases
Solution Approach 1:
The patent replaces the traditional mechanical iterative adjustment process with an automated measurement and calculation system. Pressure distribution sensors, data processing units, and algorithmic calculations substitute for manual trial-and-error adjustments, enabling rapid determination of optimal tool preparation parameters without requiring multiple iterative mechanical adjustments that downtime the machine.
Solution Approach 2:
The system applies self-service by automatically measuring pressure distribution, calculating makeready requirements, and providing actionable guidance for tool preparation. The machine itself generates the data and calculations needed for optimization, reducing the need for operator experience and iterative manual intervention, thereby minimizing setup time and maximizing productivity.
3Force
If global adjustment of punching force is applied, then overall punching capability is improved, but local pressure uniformity deteriorates
Solution Approach 1:
The patent applies local quality by measuring and analyzing pressure distribution at multiple specific locations across the punching surface simultaneously. The system calculates location-specific makeready requirements based on local pressure variations, enabling differentiated tool preparation for different areas of the tool rather than applying uniform global adjustments. This ensures each local area receives the precise adjustment it needs for optimal pressure distribution.
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 significantly reduces setup time and increases machine productivity by enabling one-step determination of preparation requirements and ensuring uniform pressure distribution, leading to improved cutting accuracy and efficiency.
Implementation Method 1
a) measuring with a pressure distribution sensor a pressure distribution in the at least one stamping and/or embossing station
Data Source
Figure 1a
Figure 1b~2b
AI summary
The method involves measuring pressure distribution in a stamping station (2) by using a foil-shaped pressure distribution sensor (30) i.e. pressure ceramic pressure sensor, that extends over a surface of a tool i.e. stamping tool (20). Adjusting requirement distribution is calculated based on the pressure distribution, and the tool is adjusted based on the adjusting requirement distribution. The adjusting requirement distribution is visualized through allocation of a color coding, where the visualization takes place through illumination of a surface of the tool with light. An independent claim is also included for a method for surface correction of cups of a flat bed die cutting and embossing machine.