Press Brake Laser Safety Device with Distance-Based Obstruction Logic
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Solution Overview
Problem
Existing press brake safety devices often incorrectly stop bending operations when laser light is obstructed by materials, leading to unnecessary interruptions and requiring an invalidation zone above the material, which is not preferable.
Innovation Solution
A press brake system with a safety device that includes a projector emitting laser light between the punch and die, an optical receiver with photodetectors to detect light obstruction, and a safety controller that compares distances to determine when to stop or continue lowering the upper table based on specific conditions, ensuring the operation is not stopped by material obstructions while stopping for intrusion objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sensor and control unit are added to detect and prevent dangerous movements, then operator safety is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical safety systems with a sensor-based detection system. Instead of using mechanical interlocks or physical barriers, the invention uses sensors to detect the position of the lower die and control units to manage the press brake operation, thereby reducing mechanical complexity while improving safety through electronic control
Solution Approach 2:
The patent introduces control units as intermediaries between the sensor detection system and the press brake actuators. These control units process sensor signals and coordinate the movement of the upper and lower dies, creating a layered control architecture that improves safety while managing system complexity through modular design
2Reliability
If the lower die movement is restricted to prevent dangerous zones, then operator safety is improved, but ease of operation deteriorates
Solution Approach 1:
The patent implements dynamic control of the lower die movement, allowing the die to move freely within safe zones while automatically restricting movement only when approaching dangerous zones. This dynamic adjustment of movement constraints maintains operational flexibility during normal work while ensuring safety through real-time position monitoring and adaptive control
Solution Approach 2:
The patent uses feedback from sensors that continuously monitor the position of the lower die relative to the workpiece and operator zones. This feedback information is fed back to the control units, which adjust the lower die movement in real-time to prevent entry into dangerous zones while allowing full range of motion when safe, thereby maintaining ease of operation without compromising safety
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 allows bending operations to continue uninterrupted when laser light is obstructed by materials and stops when necessary for intrusion objects, eliminating the need for an invalidation zone above the material, thereby enhancing safety and operational efficiency.
Implementation Method 1
an optical receiver which is mounted on the upper table, comprising a photodetector which detects the laser light passing through between the punch and the die
Data Source
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AI summary
A projector (30) emits laser light (L30) in such a way that the laser light passes through between a punch (14) and a die (24). An optical receiver (41) includes a photodetector, and determines whether the optical receiver is in a light receiving state or a light obstructing state of the laser light (L30). When an upper table (10) is lowered, a safety controller (42) controls lowering of the upper table (10) to stop, when it is determined that the optical receiver (41) is in the light obstructing state in a period in which a condition is satisfied that a first distance between a tip of the punch (14) and an upper end of a material (W) is equal to or greater than a second distance between the tip of the punch (14) and the photodetector, and controls the lowering to continue without stopping the lowering of the upper table (10) even when it is determined that the optical receiver (41) is in the light obstructing state in a period in which a condition is satisfied that the first distance is less than the second distance.