Gyroscope-Based Bending Angle Measurement for Small Workpieces
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Solution Overview
Problem
Existing bending machines face challenges in accurately measuring bending angles, particularly in environments with dust, grime, oil, and varying lighting conditions, and require expensive and bulky vision systems that are difficult to implement and maintain, especially for small workpieces.
Innovation Solution
A compact and cost-effective motion sensor unit equipped with a micro gyroscope sensor and accelerometer sensor that measures angular velocities and rotation angles to calculate bending angles in real-time, providing precise feedback for closed-loop control without the need for sophisticated software or laborious tuning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If vision systems with light sources and video cameras are used to measure bending angles, then measurement capability is provided, but the devices become bulky, expensive, and difficult to position
Solution Approach 1:
The patent replaces complex optical vision systems with a simplified sensor-based measurement approach. Instead of using light sources, video cameras, and sophisticated image processing software, the invention uses sensors (such as displacement sensors, encoders, or force sensors) to directly measure bending angles through mechanical or physical quantities, thereby reducing device complexity while maintaining measurement capability
Solution Approach 2:
The patent extracts only the essential measurement function from complex vision systems. By isolating the bending angle measurement task and implementing it through dedicated sensors integrated into the bending machine structure, the solution eliminates unnecessary components like light sources, cameras, and complex software, achieving simpler hardware and easier implementation
2Reliability
If vision systems are used for bending angle measurement, then real-time detection is achieved, but the systems are sensitive to environmental conditions such as dust, grime, oil, and lighting variations
Solution Approach 1:
The patent replaces optical vision systems that are sensitive to environmental conditions with sensor-based measurement systems that use mechanical displacement, encoder positions, or force measurements. These alternative sensing methods are not affected by dust, grime, oil, or lighting variations, thereby improving measurement reliability in harsh industrial environments
Solution Approach 2:
The patent creates an environmentally isolated measurement system by using sensors that operate independently of external environmental conditions. The sensor-based approach effectively creates an 'inert' measurement environment where dust, grime, oil, and lighting variations do not interfere with the measurement process, ensuring consistent and reliable bending angle detection
3Measurement precision
If mathematical models with material properties data are used to calculate bending angles, then bending angle can be derived from force and position, but the model must be precise and match actual material properties
Solution Approach 1:
The patent implements direct measurement systems that automatically provide bending angle data without requiring external mathematical modeling. The sensors integrated into the bending machine directly measure the bending angle through displacement, position, or force changes, eliminating the need for complex material property models and their associated complexity
Solution Approach 2:
The patent replaces mathematical modeling approaches with direct physical measurement using sensors. Instead of calculating bending angles through complex mathematical models that require precise material property data, the system directly measures the bending angle through sensor signals, thereby reducing model complexity while maintaining measurement precision
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 offers precise and reliable bending angle measurements, unaffected by environmental conditions, and can be easily implemented in various bending machines, including those with small workpieces, reducing operational complexity and costs.
Implementation Method 1
at least one motion sensor unit provided with a micro gyroscope sensor
Implementation Method 2
accelerometer sensor which measures linear accelerations
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
An apparatus for measuring a bending angle (α) between two portions (51, 52) of a workpiece (50) in a bending machine (100; 110) comprises at least a motion sensor unit (2) provided with a gyroscope sensor (3), a processing unit (10) connected to the gyroscope sensor (3) and coupling means (12, 11) for associating said motion sensor unit (2) to a portion (51, 52) of the workpiece (50) to be bent; during a bending operation of the workpiece (50) the gyroscope sensor (3) measures at least one angular velocity (ωX, ωY, ωZ) and a related rotation angle (θX, θY, θZ) of the portion (51, 52) according to an axis (X, Y, Z) and the processing unit (10) receives from the gyroscope sensor (3) data regarding the rotation angle (θX, θY, θZ) so as to calculate the bending angle (α) as a function of said rotation angle (θX, θY, θZ).