Press Brake Divided Tool Attachment Using Torque-Based Gap Elimination
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In press brake operations, attaching multiple divided tools using an automatic tool changer (ATC) often results in minute gaps between tools due to backlash, deflection, and tolerance issues, leading to potential bending scratches.
Innovation Solution
The solution involves detecting the torque of the servomotor to ensure that the divided tools abut perfectly by comparing the detected torque with a set torque value, thereby eliminating gaps between the tools during attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If position control is performed using encoder information and command positions to move the ATC, then the ATC can be positioned at the command position, but minute gaps remain between divided tools due to backlash, deflection, and tolerance issues
Solution Approach 1:
The patent applies feedback by detecting the actual position of the ATC using an encoder and comparing it with the command position. The control device calculates the difference (feedback error) and adjusts the ATC movement to compensate for backlash and positioning errors, ensuring that divided tools are positioned in direct contact without gaps.
Solution Approach 2:
The patent changes the control parameter from simple position command to position command combined with torque control. By monitoring the torque of the servomotor during ATC movement, the system can detect when tools are in direct contact (torque increase) and adjust the positioning parameters accordingly to eliminate gaps between divided tools.
2Measurement precision
If the ATC is precisely positioned at the command position through position control, then positioning accuracy is improved, but bending scratches still occur due to minute gaps between divided tools
Solution Approach 1:
The control device uses feedback from the encoder to monitor the actual position of the ATC and adjusts the positioning to ensure divided tools are in direct contact. This feedback mechanism prevents minute gaps that would cause bending scratches on the workpiece, even when the ATC is positioned at the command position.
Solution Approach 2:
The system performs preliminary positioning adjustment by detecting torque changes during ATC movement. Before the actual bending operation, the system ensures tools are in direct contact by detecting the torque increase that occurs when tools abut against each other, thereby preventing bending scratches in advance.
3Extent of automation
If divided tools are attached using an ATC with standard position control, then automation is improved, but minute gaps remain due to backlash and deflection
Solution Approach 1:
The patent maintains full automation while adding feedback control. The encoder provides real-time position feedback during ATC operation, and the control device automatically adjusts the positioning to eliminate gaps between divided tools, combining automation with precision control.
Solution Approach 2:
The system enhances the automated positioning parameter by incorporating torque detection. The control device monitors servomotor torque during ATC movement and uses this information to adjust positioning parameters, ensuring divided tools are in direct contact while maintaining automatic operation.
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 ensures that the divided tools are securely attached without gaps, preventing bending scratches and improving the precision of the tool attachment process.
Implementation Method 1
whether or not the divided tools have abutted on each other is detected by detecting the torque of the servomotor for moving the automatic tool changers
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Different divided tools P2, D2 are attached to tool attachment portions using automatic tool changers (13U, 13L) in proximity to slit tools (P1, D1) that have already been attached to tool attachment portions (9U, 9L). The attached different divided tools (P2, D2) are moved toward the previously attached divided tools (P1, D1) using the automatic tool changers (13U, 13L), and the different divided tools (P2, D2) are caused to abut on the previously attached divided tools (P1, D1). In a case in which a torque of a servomotor for moving the automatic tool changers (13U, 13L) in a left-right direction has reached a setting value set in advance, the different divided tools are detected to have abutted on the previously attached divided tools, and the moving of the different divided tools is stopped.