Laminate Molding Control with Position-Based Thickness Measurement
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Solution Overview
Problem
Existing laminate molding systems face challenges in accurately measuring and controlling the thickness of softened laminates during multiple press stages, leading to inconsistent quality in the final molded product due to difficulties in detecting torque changes and maintaining consistent pressurization speed.
Innovation Solution
A laminate molding system with multiple press apparatuses equipped with servomotors, load cells, and position sensors, allowing for precise measurement and control of physical quantities during and after each press stage to stabilize the molding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the lower press block is continuously raised at constant speed to prevent long molding cycles, then productivity is improved, but the softened temporary laminate cannot be accurately measured for thickness control
Solution Approach 1:
The patent measures the thickness of the temporary laminate during the raising process of the lower press block, before the laminate is excessively pressed and softened. By performing the measurement action in advance during the controlled raising phase, the system captures accurate thickness data while the laminate is still in a measurable state, resolving the contradiction between continuous raising for productivity and accurate measurement for quality control
2Device complexity
If torque detection is used to detect contact with the temporary laminate, then the control mechanism is simplified, but the torque increase is only detectable after excessive pressure is applied, resulting in inaccurate thickness measurement
Solution Approach 1:
The patent replaces the mechanical torque detection method with a position-based detection system using a linear scale and position sensor. Instead of relying on torque changes that only become detectable after excessive pressure is applied, the system directly measures the position of the lower press block relative to the upper press block, enabling accurate thickness measurement from the start of the raising process without requiring complex torque sensing mechanisms
3Manufacturing precision
If the pressurization stroke is set to be shorter than the laminate thickness by 20 μm, then the target thickness is achieved, but the pressurization stroke does not stabilize and final product quality varies
Solution Approach 1:
The patent implements a feedback control system that measures the actual thickness of the temporary laminate using a linear scale and position sensor during the raising process. The measured thickness value is fed back to the control unit, which adjusts the pressurization stroke accordingly. This closed-loop feedback mechanism stabilizes the pressurization stroke by continuously adapting to actual laminate conditions, ensuring consistent final product quality while achieving the target thickness control
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
Enables accurate thickness control and stabilization of the molding process, resulting in consistent quality of the final laminate product by using servomotors, load cells, and position sensors to measure and adjust pressurization.
Implementation Method 1
a pressing force during pressure-molding or after pressure-molding by the press apparatus in the previous step is measured
Implementation Method 2
a position during or after pressure-molding by the press apparatus in the previous step is measured
Data Source
AI summary
A control method of a laminate molding system is a control method of a laminate molding system in which at least two press apparatuses are consecutively provided and a laminate molded product having been pressure-molded by the press apparatus in a previous step is further pressure-molded by the press apparatus in a subsequent step, wherein a physical quantity during pressure-molding or after pressure-molding by the press apparatus in the previous step is measured and the physical quantity is used to control the press apparatus in the subsequent step. Accordingly, a control method of a laminate molding system and a laminate molding system capable of favorably performing laminate molding of a laminate molded product can be provided.