Press Brake Optical Alignment for Bending Precision
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Solution Overview
Problem
Existing methods for bending sheet metal workpieces lack precision, leading to inconsistent results due to inadequate monitoring and correction of the bending line and angular symmetry during the bending process.
Innovation Solution
A method utilizing a press brake with a safety system that includes a light source and optical detection means to monitor the bending process, allowing for precise positioning and correction of the workpiece by generating control signals for re-bending, ensuring the bending line and angular symmetry remain within permissible deviations from the central plane.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional bending methods are used, then the bending process is simple and fast, but the bending accuracy and consistency are insufficient
Solution Approach 1:
The method performs a pre-bending operation before the final bending. The workpiece is first bent to a pre-bending angle, then unloaded to measure the actual bending angle and assess forming behavior including springback. This preliminary action provides data for calculating the final bending angle, significantly improving bending accuracy while managing system complexity through a structured two-stage process
Solution Approach 2:
The system measures the actual bending angle after pre-bending and uses this measurement to calculate the required final bending angle. The control device receives feedback about the workpiece's forming behavior and adjusts the final bending operation accordingly. This closed-loop feedback mechanism ensures high bending accuracy by compensating for material variations and springback effects
Solution Approach 3:
The patent replaces traditional mechanical alignment and positioning systems with an optical measurement system. A light source and optical detection means are used to monitor the workpiece position and bending line location, providing precise measurement data without complex mechanical fixtures or alignment mechanisms
2Measurement precision
If the workpiece is unloaded for measurement, then the bending angle can be accurately measured, but the workpiece position may change causing misalignment
Solution Approach 1:
After the workpiece is unloaded and its position is measured using the optical system, the control device receives feedback about any position deviations. The system then generates control signals to correct the workpiece position or adjusts the final bending operation to compensate for the displacement, ensuring that the bending line remains correctly positioned despite the unloading movement
Solution Approach 2:
The patent uses an optical measurement system (light source and optical detection means) to monitor workpiece position instead of mechanical fixtures or contact-based measurement devices. This non-contact measurement method allows accurate position detection without mechanical interference, enabling reliable measurement even after unloading
3Productivity
If the bending line position deviates from the center plane, then the bending operation can proceed, but the accuracy and symmetry of the workpiece are compromised
Solution Approach 1:
The optical detection system continuously monitors the bending line position relative to the center plane during the bending operation. The control device receives feedback about position deviations and generates control signals to correct the workpiece position or adjust the bending tools, ensuring the bending line remains within permissible deviation limits and maintaining both accuracy and operational continuity
Solution Approach 2:
The patent establishes a defined center plane as the reference for symmetric bending operations. By monitoring and correcting deviations from this central reference, the system ensures symmetrical bending results. The control device uses the center plane as an asymmetric reference point to generate corrective actions that restore symmetry when deviations occur
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 method enhances the accuracy of bending by preventing undesirable positional changes and ensuring symmetrical placement, allowing for consistent bending angles and reducing rejects by blocking further bending until proper alignment is achieved.
Implementation Method 1
the safety system comprises a light source arranged on a first longitudinal side of the press brake and an optical detection means arranged on a second longitudinal side of the press brake
Data Source
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AI summary
The invention relates to a method for bending a workpiece (2) along a straight bending line (27) by means of a first bending tool (5) and a second bending tool (6) of a press brake (3), wherein, during the approaching motion between the first bending tool (5) and the second bending tool (6), the region between the two bending tools (5, 6) is monitored for the presence of obstacles by a control device (24) by means of a safety system (30). Then, the position of the bending line (27) of the relieved and pre-bent workpiece (2) in relation to a center plane (40) of the first bending tool (5) and/or of the second bending tool (6) is determined by means of the safety system (30). On the basis of a control signal, the position of the workpiece (2) is corrected until the position deviation (42) of the bending line (27) lies within a permissible maximum deviation from the center plane (40). Then, the workpiece (2) is bent to the final angle thereof.