Forming Press Force Control for Precise Pressure Distribution
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Solution Overview
Problem
Existing methods for operating forming presses struggle to accurately control pressure distribution between the sheet and sheet holder during the forming process, especially in bent configurations, due to difficulties in measuring and converting feed differentials into signals for force actuators, leading to suboptimal forming results.
Innovation Solution
Incorporating a forming simulation that models press and tool components as deformable bodies with elastic behavior, using force sensors and actuators to measure and adjust forces in real-time, ensuring desired force values are maintained throughout the process without needing to convert feed differentials into signals for force actuators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If force sensors and actuators are used to measure and adjust forces in real-time, then pressure distribution control precision is improved, but device complexity increases
Solution Approach 1:
Force sensors measure actual forces during the forming process and provide feedback to the control system, which then adjusts force actuators to maintain desired force values. This closed-loop feedback mechanism enables precise pressure distribution control by continuously monitoring and correcting deviations from target values.
Solution Approach 2:
The patent replaces traditional mechanical linkages and manual adjustment mechanisms with force sensors and controlled actuators. This substitution of mechanical systems with sensor-actuator systems enables more precise and automated control of pressure distribution, reducing reliance on mechanical complexity while improving control accuracy.
2Manufacturing precision
If forming simulation with elastic behavior modeling is used, then forming result accuracy is improved, but calculation time and computational resources increase
Solution Approach 1:
A forming simulation is performed before the actual forming process to determine desired force values as a function of time. This preliminary simulation with elastic behavior modeling predicts the optimal force profile, which is then used as a reference during the actual process, avoiding the need for complex real-time calculations.
Solution Approach 2:
The force profile determined from the preliminary simulation with elastic behavior modeling is continuously applied during the actual forming process. This ensures that the beneficial effects of accurate elastic modeling are maintained throughout the entire forming operation without requiring repeated complex calculations.
3Stability of the object's composition
If desired force values are determined through simulation and controlled in real-time, then forming result consistency is improved, but control system complexity increases
Solution Approach 1:
Force sensors provide real-time feedback on actual forces during forming, which are compared against desired force values from simulation. The control system uses this feedback to adjust actuators, ensuring consistent forming results despite variations in material properties or tool wear.
Solution Approach 2:
The forming simulation creates a virtual model that replicates the physical forming process, allowing desired force profiles to be determined in advance. This virtual copy guides the actual forming process, ensuring consistency by reproducing optimal conditions without requiring complex real-time control adjustments.
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 allows for precise control of pressure distribution, ensuring process forces align with simulation predictions, resulting in consistent and accurate forming results across different forming presses, regardless of construction tolerances and stress.
Implementation Method 1
actual values of forces which act on at least one press component or tool component are determined by means of a force sensor
Implementation Method 2
the force actuator is activated via a control circuit in such a manner that the actual values correspond to the desired values from the forming simulation
Implementation Method 3
The hydraulic cylinders here exert a counterforce which is conducted via the pressure pad into the press sleeves and lower air pins into the sheet holder
Implementation Method 4
the ram moves vertically downward and in doing so displaces the entire system consisting of sheet holder, press sleeves and pressure pad
Data Source
AI summary
A method for operating a forming press which includes a plurality of press components and a plurality of tool components. The forming press has at least one force sensor and at least one force actuator, each arranged in a press and/or tool component. A forming simulation is carried out, which takes into consideration an elastic behavior of the press and/or tool components. Target values of forces acting on at least one press and/or tool component are determined by the forming simulation. A forming process is carried out by the forming press. During the forming process, actual values of forces acting on the press and/or tool components are measured by the force sensor and the force actuator is actuated via a control loop such that the actual values correspond to the target values from the forming simulation.