Forming Device Control for Geometric Tolerance via Feedback
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Solution Overview
Problem
Current forming processes for mass-producing workpieces with precise geometric tolerances are time-consuming and expensive due to the need for recurring setup and test forming, especially when producing the same workpieces repeatedly, as they require manual adjustment of tool positions, feed paths, and pressing forces to maintain specified tolerances.
Innovation Solution
A method where the movement device in a forming process is controlled using measured variables such as forming force, temperature, and geometric properties from previous steps to adjust the forming process in real-time, allowing for feedback loops to maintain predetermined geometric properties, thereby reducing setup time and improving tolerance consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustment of tool positions, feed paths, and pressing forces is performed to maintain specified tolerances, then manufacturing precision is improved, but loss of time and productivity deteriorate due to recurring setup and test forming
Solution Approach 1:
The patent implements feedback control by measuring the actual geometric properties of formed workpieces and using this information to automatically adjust forming parameters for subsequent workpieces. This eliminates manual setup and test forming while maintaining precision, directly resolving the contradiction between manufacturing precision and setup time.
Solution Approach 2:
The patent replaces manual mechanical adjustment of tool positions and pressing forces with automated control systems that use measured data to adjust parameters. This substitution eliminates time-consuming manual operations while maintaining the precision required for geometric tolerances.
2Manufacturing precision
If manual setup and test forming are performed to achieve specified tolerances, then manufacturing precision is improved, but device complexity increases due to multiple adjustment parameters
Solution Approach 1:
The feedback control system automatically manages the complexity of multiple adjustment parameters by using measured geometric properties to calculate and apply the necessary adjustments. This eliminates the need for operators to manually coordinate multiple parameters, reducing operational complexity while maintaining precision.
Solution Approach 2:
The system performs self-adjustment by automatically modifying forming parameters based on measured workpiece properties. This self-service capability eliminates the need for complex manual setup procedures and reduces the complexity associated with multiple adjustment parameters.
3Manufacturing precision
If forming parameters are adjusted to account for material and thermal fluctuations, then manufacturing precision is improved, but extent of automation must increase requiring real-time measurement and control
Solution Approach 1:
The patent implements feedback control by measuring the actual geometric properties of formed workpieces and using this information to automatically adjust forming parameters for subsequent workpieces. This eliminates manual setup and test forming while maintaining precision, directly resolving the contradiction between manufacturing precision and setup time.
Solution Approach 2:
The patent replaces manual mechanical adjustment of tool positions and pressing forces with automated control systems that use measured data to adjust parameters. This substitution eliminates time-consuming manual operations while maintaining the precision required for geometric tolerances.
Data Source
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AI summary
The invention relates to a method for carrying out a forming process (13) by means of a forming device comprising a control device (56), at least one forming tool and at least one counter tool for forming a workpiece from a raw material, and a movement device for moving the forming tool and the counter tool relative to each other, wherein the movement device is controlled by the control device (56) with a manipulated variable yRs, such that the forming tool and/or the counter tool is driven to move into a forming position or to achieve a forming force (Fi) in order to provide the workpiece with a predetermined geometric property by acting upon it with the forming tool and the counter tool, wherein the control of the movement device takes into account at least one metrologically determined quantity that influences the achievement of the predetermined geometric property of the workpiece.where the measured quantity is a forming force exerted on the workpiece by means of the forming device or a quantity dependent thereon and/or a temperature (Tref) of the forming device and/or a geometric property of the workpiece and/or a geometric property of a workpiece formed by means of the forming device in a previous forming process.