Press Beam Crowning With Piezo Compensation for Sagging Control
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Solution Overview
Problem
Existing methods for compensating deviations in deforming operations between press beams, such as sagging and tool wear, are either not adjustable during the process or rely on expensive hydraulic systems prone to leakage and fouling, limiting real-time correction and efficiency.
Innovation Solution
An electromechanical compensation method using a movable compensating element with a piezoelectric actuator, which adjusts resistance force to correct deviations locally and dynamically, avoiding hydraulic systems and enabling quick, accurate corrections without the need for extensive adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydraulic systems are used for crowning compensation, then compensation during deforming operation is achieved, but cost increases and risk of leakage and fouling occurs
Solution Approach 1:
The patent replaces the hydraulic system with a mechanical system consisting of a crowning mechanism with adjustable wedges and a drive unit. The drive unit mechanically adjusts the position of the crowning mechanism to compensate for beam sagging during the deforming operation, eliminating the need for hydraulic fluids and associated leakage risks.
Solution Approach 2:
The patent employs a mechanical drive unit that can be easily replaced or adjusted, rather than relying on complex hydraulic systems that are prone to leakage and fouling. This approach uses simpler, more reliable mechanical components that are less susceptible to harmful effects.
2Manufacturing precision
If wedge-shaped protrusions with varying angles are used in crowning mechanism, then local inaccuracies are corrected, but adaptability to different deviation patterns is limited
Solution Approach 1:
The patent employs a drive unit that can dynamically adjust the position of the crowning mechanism during the deforming operation. This allows the system to adapt to different deviation patterns and correct inaccuracies in real-time, rather than being limited to fixed wedge angles designed for specific conditions.
Solution Approach 2:
The patent allows for changing the position and configuration of the crowning mechanism through the drive unit, enabling adjustment of compensation parameters to match different deviation patterns. This provides versatility in correcting various types of inaccuracies without being constrained by fixed geometric configurations.
3Shape
If strips are displaced in longitudinal direction to bend tool holder, then crowning is achieved, but adjustment during deforming operation is not possible
Solution Approach 1:
The patent incorporates a drive unit that can adjust the position of the crowning mechanism dynamically during the deforming operation. This enables real-time correction of beam sagging and maintains accurate tool holder positioning throughout the process, rather than requiring pre-set fixed configurations.
Solution Approach 2:
The patent implements a control system that monitors the deforming operation and adjusts the crowning mechanism accordingly. This feedback mechanism allows the system to detect deviations and automatically correct them during the process, achieving automated real-time adjustment.
4Manufacturing precision
If hydraulic cylinders are used to compensate beam sagging, then deviation correction during operation is achieved, but device complexity and space requirements increase
Solution Approach 1:
The patent replaces complex hydraulic cylinders with a simpler mechanical drive unit and crowning mechanism. This mechanical system achieves the same function of compensating beam sagging during operation but with reduced complexity, fewer components, and lower space requirements.
Solution Approach 2:
The patent extracts the essential function of beam sagging compensation from the complex hydraulic system and implements it through a simplified mechanical crowning mechanism driven by a compact drive unit, eliminating unnecessary complexity while maintaining correction capability.
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 solution ensures consistent product quality by allowing real-time deviation correction, reducing waste, and providing a compact, cost-effective, and reliable compensation mechanism that can be integrated into existing presses.
Implementation Method 1
a movable compensating element with a piezoelectric actuator, which adjusts resistance force
Data Source
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AI summary
The invention relates to a method for compensating deviations in a deforming operation between two beams of a press, comprising of arranging one or more compensating element at a suitably chosen location in the press, detecting the deviations and moving the compensating element (s) relative to the beams by ( electro ) mechanical means during the deforming operation such that the detected deviations are compensated. The compensating elements can be moved here to an over-compensating position prior to the deforming operation and pressed out of their over-compensating position during the operation by the load on the beam, wherein each compensating element exerts an adjustable resistance force on surrounding parts of the press. It is conversely possible for the compensating elements each to be pressed stepwise to a position compensating the detected deviations during the deforming operation. It is possible to use (piezoelectric) actuators to exert the resistance force and/or to move the compensating elements. The invention further relates to a device with which this compensation method can be performed.