Forming Tool with Sensor-Driven Adaptive Guides
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Solution Overview
Problem
Conventional forming tools struggle to maintain optimal blank positioning during production phases due to process fluctuations, leading to suboptimal deformation distribution in formed parts, which is time-consuming and not guaranteed to reach the optimal operating point.
Innovation Solution
A forming tool with adjustable guides and a sensor arrangement that detects characteristic values related to deformation distribution, allowing a control device to adjust the guides to achieve a predetermined target deformation distribution, thereby optimizing blank forming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If preset fixed guides are used for blank positioning, then the structure is simple and easy to manufacture, but the forming tool cannot adapt to process fluctuations and maintain optimal deformation distribution
Solution Approach 1:
The patent applies the dynamics principle by replacing fixed guides with adjustable guides that can dynamically change their position during the production phase. The guides are equipped with actuators that enable them to move in the transverse direction based on feedback from sensors, allowing the forming tool to adapt to process fluctuations while maintaining optimal blank positioning and deformation distribution.
Solution Approach 2:
The patent implements feedback by using sensors to detect characteristic values related to deformation distribution and using this information to automatically adjust the guide positions. The control device receives sensor data and commands actuators to modify guide positions, creating a closed-loop control system that continuously optimizes blank positioning based on actual forming conditions.
2Manufacturing precision
If manual empirical adjustments are made to optimize blank positioning, then the optimization process is simple to implement, but it is very time-consuming and does not guarantee reaching the optimal working point
Solution Approach 1:
The patent uses feedback control to automatically adjust blank positioning based on sensor-detected deformation characteristics. The control device continuously monitors deformation distribution through sensors and automatically modifies guide positions to achieve optimal deformation patterns, eliminating time-consuming manual trial-and-error adjustments while ensuring precise deformation control.
Solution Approach 2:
The patent replaces manual mechanical adjustment with an automated control system that uses sensors and actuators. Instead of operators manually positioning guides based on experience, the system uses electronic sensing and actuation to automatically achieve optimal blank positioning, significantly reducing optimization time while improving precision.
3Measurement precision
If fixed guides are preset during training phase, then the setup is simple and quick, but the optimal operating point remains quantitatively undefined during production phase
Solution Approach 1:
The patent implements feedback control that enables quantitative definition of the optimal operating point during production. Sensors detect characteristic values of deformation distribution, and the control device uses this feedback to automatically adjust guide positions, transforming the qualitative manual optimization process into a quantitative automated control system that precisely defines and maintains optimal operating parameters.
Solution Approach 2:
The patent applies self-service by enabling the forming tool to automatically optimize its own operation during production. The system uses its own sensors to detect deformation characteristics and automatically adjusts its own guide positions through actuators, eliminating the need for external manual intervention and achieving quantitative optimization autonomously.
Data Source
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AI summary
Forming tool and method for optimizing board forming in a forming tool. The forming tool (1) has two tool parts, which are movable relative to one another in a working direction, for holding and forming a board therebetween in order to form a formed part (UT) therefrom, a plurality of position adapters (10.1-10.8) for contacting a peripheral edge (PL1) of the board in order to position the latter transversely to the working direction, wherein the position adapters each have an actuator (11) via which a board-contacting element (12) of the position adapter is displaceable in order to position the board transversely to the working direction, a sensor arrangement (20) which is set up to sense at least one characteristic (a1.1-a4.1) corresponding to each position adapter, said characteristic (a1.1-a4.1) correlating with a shape-change distribution in the formed part, and a control device which is connected to the actuators and the sensor arrangement and is set up to actuate the actuators, on the basis of the sensed characteristics, to displace the board-contacting elements such that a predetermined nominal shape-change distribution is achieved on the formed-part side.