Optical Workpiece Positioning for Adaptive Forming Accuracy
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Solution Overview
Problem
Existing forming processes for metallic workpieces, such as those used in motor vehicle body production, face challenges in achieving consistent quality due to variations in workpiece dimensions and relative location during the forming process, leading to geometric inaccuracies and reduced component quality.
Innovation Solution
A method that utilizes an optical acquisition device to gather information on the relative location of workpieces within the forming device, which is then used to determine adaptive parameters for optimizing the forming process. These parameters are calculated based on data from previous forming processes, allowing for real-time adjustments to ensure precise alignment and material flow control, thereby enhancing the quality of the formed components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional forming processes are used without adaptive adjustments, then the production process is simple and fast, but the geometric accuracy and quality of formed components deteriorate due to variations in workpiece dimensions and relative location
Solution Approach 1:
The patent applies preliminary action by measuring workpiece dimensions and relative location before the forming process, storing this data in advance, and using it to determine adaptive parameters that are applied during forming. This pre-measurement and pre-calculation approach enables precision improvement without adding complex real-time control systems during the actual forming operation.
Solution Approach 2:
The patent implements feedback by using measured workpiece data from previous processes to adjust forming parameters in subsequent processes. The optical acquisition device captures workpiece characteristics, this information is stored and processed, and the resulting adaptive parameters are applied to compensate for dimensional variations, creating a closed-loop system that improves geometric accuracy through iterative refinement.
2Manufacturing precision
If adaptive parameters are determined based on measured workpiece data, then the quality of formed components is improved, but the production time increases due to additional measurement and calculation steps
Solution Approach 1:
The patent performs measurements and determines adaptive parameters in advance, before the actual forming process begins. By pre-processing the workpiece data and calculating the necessary parameter adjustments beforehand, the system avoids time-consuming operations during the forming cycle itself, thus maintaining production efficiency while improving quality consistency.
Solution Approach 2:
The system uses the workpiece's own measured dimensions and location data to determine its own forming parameters. Each workpiece essentially adjusts its own forming process based on its unique characteristics, eliminating the need for manual intervention or complex external control systems, thereby maintaining fast production cycles while achieving consistent quality.
3Manufacturing precision
If cushion cylinder forces are adjusted to control material flow, then the geometric accuracy of formed components is improved, but the complexity of force control and parameter adjustment increases
Solution Approach 1:
The patent uses feedback from measured workpiece data to automatically determine the required cushion cylinder forces. Instead of requiring manual adjustment of multiple force parameters, the system calculates the appropriate forces based on actual workpiece dimensions and location, then applies these forces through the cushion cylinders. This automated feedback-based approach simplifies the control process while maintaining precise material flow control.
Solution Approach 2:
The patent changes the cushion cylinder force parameters based on measured workpiece characteristics. By adjusting these forces according to actual workpiece data rather than using fixed predetermined values, the system achieves better material flow control and geometric accuracy. The parameters are adapted to match the specific workpiece being formed, improving precision without requiring complex manual control procedures.
Data Source
AI summary
A method for optimizing forming processes for forming workpieces, in which information characterizing a relative position of a workpiece inserted in a forming device in relation to at least one reference point of the forming device is detected by means of an optical detection device, wherein at least one parameter for adjusting the respective forming process for forming the respective workpiece is determined during a respective forming process, depending on the information detected during the respective forming process and depending on the information detected during the previous forming processes performed prior to the respective forming process and stored in an electronic computing device.