Press Brake Position Correction for Continuous Bending Accuracy
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Solution Overview
Problem
Existing bending machines require frequent operator intervention for accuracy confirmation and correction, leading to instability in processed part quality and increased burden on operators.
Innovation Solution
A bending method and system that acquire reference values for each processed part, calculate secular change corrections based on measurement values, and automatically reset the pushing amount or original position during operation, reducing the need for manual accuracy confirmation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the bending machine operates continuously for long-time production, then productivity increases, but the bending accuracy deteriorates due to secular changes in the machine structure
Solution Approach 1:
The system performs preliminary measurement of the reference position before bending operations start, and pre-calculates the secular change correction value. This preliminary action allows the machine to compensate for secular changes proactively during continuous operation, maintaining bending accuracy without interrupting productivity.
Solution Approach 2:
The system implements a feedback mechanism where the actual bending results are measured and compared with target values. The secular change correction value is updated based on this feedback, allowing continuous adjustment of the pushing amount to maintain accuracy during long-time operation.
2Manufacturing precision
If the operator performs frequent accuracy confirmation and correction, then bending accuracy is maintained, but the operation burden increases and productivity decreases
Solution Approach 1:
The bending machine performs self-correction by automatically measuring its own reference position, calculating secular change correction values, and adjusting the pushing amount without operator intervention. This self-service capability eliminates the need for frequent manual accuracy confirmation, maintaining precision while preserving productivity.
Solution Approach 2:
The system replaces manual measurement and correction operations with automated sensing and control systems. Sensors detect the reference position, and the control unit automatically calculates and applies correction values, substituting the operator's mechanical actions with an automated electro-mechanical system.
3Manufacturing precision
If the machine is stopped for correction operations, then bending accuracy is restored, but production time is lost and productivity decreases
Solution Approach 1:
The system maintains continuous bending operations by performing secular change corrections during idle periods between bends or using non-interfering measurement methods. The useful action of bending continues uninterrupted, while corrections are applied in real-time or between cycles, eliminating production time losses.
Solution Approach 2:
The system performs measurement and calculation of correction values during idle moments before the next bending operation, so that when correction is needed, it is already prepared and can be applied immediately without stopping production flow.
4Manufacturing precision
If the pushing amount is frequently adjusted manually, then bending accuracy is maintained, but the complexity of operation increases
Solution Approach 1:
The bending machine automatically performs all pushing amount adjustments based on measured secular changes. The system serves itself by detecting position drift, calculating correction values, and modifying the pushing amount without requiring operator knowledge or manual intervention, maintaining simplicity while ensuring accuracy.
Solution Approach 2:
The system uses feedback from position sensors to automatically adjust the pushing amount. The control unit receives information about secular changes and automatically modifies operational parameters, eliminating the need for operators to understand complex adjustment procedures.
Data Source
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AI summary
A bending method includes acquiring a reference value of an original position of a punch with respect to a die for each processed part before an operation of bending of a workpiece by a bending machine including the punch and the die is started, storing each of the acquired reference values in association with each of the processed parts, reading the reference value associated with the processed part to which the bending is to be executed, acquiring a measurement value of the original position after the operation of the bending of the workpiece is started, calculating, based on the acquired measurement value, a secular change amount from the reference value or a previous measurement value as a secular change correction value for a pushing amount of the punch with respect to the die or the original position of the punch, and resetting, for each predetermined trigger condition, the pushing amount or the original position by using the secular change correction value during an automatic operation of the bending of the workpiece.