Press Brake Control via Dynamic Force Monitoring
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Solution Overview
Problem
Existing methods for operating bending presses, such as press brakes, do not efficiently minimize cycle time due to delays in initiating the rapid return stroke, which affects the deformation of machine components and overall forming process efficiency.
Innovation Solution
The method involves automatically detecting the time to initiate the rapid return stroke based on varying adjustment forces, using parameters like pressure sensors to control the hydraulic system, ensuring a gentle operation and reducing cycle time by relieving deformation forces and adapting to different machine configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fixed safety time delay is used to initiate the rapid return stroke, then the operation is gentle and safe, but the cycle time is increased
Solution Approach 1:
The patent applies dynamics by transitioning from a fixed, static safety time delay to a dynamic, adaptive timing mechanism. The control device continuously monitors adjustment forces during the forming process and automatically determines the optimal moment to initiate the rapid return stroke based on real-time force conditions. This dynamic adaptation allows the system to minimize cycle time while maintaining safe operation by only initiating return stroke when adjustment forces have sufficiently decreased.
Solution Approach 2:
The patent implements feedback by using detection means to continuously monitor adjustment forces during the forming process. The control device receives real-time feedback about the current adjustment force level and uses this information to automatically determine when to initiate the rapid return stroke. This closed-loop feedback mechanism replaces fixed timing with intelligent, condition-based decision-making, optimizing both safety and cycle time.
2Productivity
If the rapid return stroke is initiated earlier to reduce cycle time, then productivity increases, but harmful load shocks occur on machine components
Solution Approach 1:
The control device uses real-time feedback from detection means monitoring adjustment forces to determine the precise moment when it is safe to initiate the rapid return stroke. By continuously measuring adjustment forces and comparing them against predetermined thresholds, the system automatically identifies the optimal transition point that minimizes cycle time while preventing harmful load shocks on machine components.
Solution Approach 2:
The patent applies parameter changes by monitoring the adjustment force parameter during the forming process and using its variation to control the timing of the rapid return stroke initiation. Instead of using fixed time parameters, the system dynamically adjusts the return stroke timing based on the actual adjustment force parameter, allowing earlier initiation when forces are low and preventing harmful load shocks.
3Reliability
If adjustment forces are reduced during the relief phase, then machine components are protected from excessive load, but the forming process time increases
Solution Approach 1:
The patent applies dynamics by implementing a dynamic relief phase where adjustment forces are gradually reduced based on real-time monitoring rather than using fixed, prolonged relief timing. The control device continuously monitors adjustment forces and automatically transitions from the relief phase to the rapid return stroke when force thresholds are met, optimizing both component protection and process time through adaptive force management.
Solution Approach 2:
The patent applies preliminary action by proactively managing the relief phase to gradually reduce adjustment forces before the rapid return stroke is initiated. The control device prepares the system for the upcoming return stroke by controlling the gradual force reduction in advance, ensuring components are protected while minimizing the duration of the relief phase through intelligent timing based on detected force conditions.
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 approach reduces cycle time by allowing a controlled relief phase, minimizing load on machine components, and adapting to varying adjustment forces, resulting in a more efficient forming process with reduced deformation and faster return strokes.
Implementation Method 1
detected by detection means with the aid of which information about the load state can be derived
Data Source
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AI summary
The invention describes a method for operating a press brake, in particular a bending press (1), with a machine frame (2) consisting essentially of side supports (3, 4) and a table beam (5), and with a press beam (8) that is adjustable relative to the table beam (5) by means of a drive device (11). A control and/or regulating device (34) is connected to a displacement measuring device (42) for determining the displacement of the press beam (8) between an upper and lower reversal position and to at least one detection means (32) for detecting at least one physical parameter for determining the adjustment force applied to the press beam (8) by the drive device (11) or the drive element (9, 10).A reaction force (71) determined in the lower reversal position from the parameter recorded by the detection means (32) forms an actual value which is reduced to a predetermined target value for applying pressure to the drive means (9, 10) for a rapid return stroke according to a control function stored in the data storage (36) or computer (35).