Forming Device Sensor Placement for Safety and Continuity
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Solution Overview
Problem
Existing forming devices for plastic deformation of components, such as sheet metal, often experience disruptions in the machining process due to unintentional intrusion into protective fields, leading to unwanted shutdowns and potential injuries to operating personnel, which are not effectively addressed by traditional protective systems.
Innovation Solution
A forming device with a sensor device that emits radiation from outside the working area, allowing for contactless monitoring of the work area without obstructing the processing component, and featuring adjustable vertical and horizontal distances to detect deformation states and prevent manual intervention, thereby minimizing the risk of unintentional shutdowns and injuries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If protective systems such as light barriers are arranged in the working area to protect operating personnel, then safety against injuries is improved, but the machining process is disrupted by unintentional intrusion leading to unwanted shutdowns
Solution Approach 1:
The emitter opening is positioned in a region of a pivot point of the relative movement between lower part and upper part, allowing radiation to pass through a specific zone that defines the danger area without requiring sensors throughout the entire working area. This dimensional positioning of the protection zone reduces false shutdowns while maintaining safety.
Solution Approach 2:
The protective radiation field is concentrated specifically in the danger area around the pivot point where the risk of injury is highest, rather than covering the entire working area. This localized protection approach minimizes disruptions from unintentional intrusion in safe zones while maintaining safety where needed.
2Measurement precision
If sensor devices are arranged inside the working area to monitor the danger zone, then monitoring precision is improved, but the sensor device parts obstruct the processing component and interfere with work steps
Solution Approach 1:
The emitter component is extracted from the working area and positioned outside on the machine frame, with only the necessary radiation beam passing through the working area. This removes the physical obstruction problem while maintaining monitoring capability through the emitted radiation field.
Solution Approach 2:
Radiation serves as an intermediary between the emitter component outside the working area and the monitoring function. The radiation passes through the working area and danger zone without requiring physical sensor components inside the working area, thus avoiding obstruction of processing components.
3Reliability
If a large protective field is established to cover the entire working area, then comprehensive safety coverage is improved, but the probability of unintentional shutdowns increases due to larger monitoring zone
Solution Approach 1:
The protective radiation field is concentrated specifically in the danger area around the pivot point where the risk of injury is highest, rather than covering the entire working area. This localized protection approach minimizes disruptions from unintentional intrusion in safe zones while maintaining safety where needed.
Solution Approach 2:
The emitter opening is positioned in a region of a pivot point of the relative movement between lower part and upper part, allowing radiation to pass through a specific zone that defines the danger area without requiring sensors throughout the entire working area. This dimensional positioning of the protection zone reduces false shutdowns while maintaining safety.
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
The solution effectively reduces the probability of unintentional shutdowns and enhances safety by ensuring only the necessary areas are secured, allowing for continuous operation while protecting personnel from injuries, with the added benefit of detecting deformations and material inhomogeneities early.
Implementation Method 1
a sensor device for at least regionally, contactless monitoring of the work area by means of radiation that can be emitted by the sensor device
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
The invention relates to a forming device (10) for the plastic deformation of a component (54), in particular a sheet metal component, comprising an upper part (12) of the forming device (10) and a lower part (14) of the forming device (10), between which the component (54) can be fixed and deformed under a relative movement (20) between the lower part (14) and the upper part (12), comprising a machine frame (22) accommodating the upper part (12) and the lower part (14), which at least partially limits a working area (28) of the forming device (10) in which the component (54) can be deformed, and comprising a sensor device (40) for at least partially, non-contact monitoring of the working area (28) by means of radiation (42) emitted by the sensor device (40).The sensor device (40) has at least one emitter component (46) by means of which the radiation (42) can be emitted through at least one emitter opening (34) in the machine frame (22) into the working area (28), wherein the emitter opening (34) is arranged in a region of a pivot point (18) of the relative movement (20) between the lower part (14) and the upper part (12).