Press Brake Divided Tool Alignment Using Torque Feedback
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Solution Overview
Problem
In press brake operations, the automatic tool changer (ATC) may leave minute gaps between divided tools due to backlash, deflection, and drawing tolerance, leading to bending scratches during the bending of plate-shaped workpieces.
Innovation Solution
The method involves using a first and second automatic tool changer to retain divided tools in an immovable state and perform a pulling operation, with the control device choosing between abutting against the tool's side surface or engaging with its engagement hole, and stopping the movement when a preset torque value is reached to ensure proper alignment and contact between tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If position control based on encoder information is used to position the ATC, then the ATC can be positioned accurately at the instructed position, but minute gaps may remain between the respective divided tools due to backlash, deflection, and drawing tolerance
Solution Approach 1:
The patent employs feedback through torque detection to monitor the pulling operation in real-time. When the torque reaches a predetermined value, the system automatically stops the pulling operation, ensuring that divided tools are brought into contact without excessive force. This feedback mechanism resolves the contradiction by providing precise control that accounts for mechanical imperfections like backlash and deflection.
Solution Approach 2:
The system uses the inherent mechanical properties of the divided tools themselves (their resistance to being pulled together) to determine when they are properly aligned. By detecting the torque required to bring tools into contact and using this information to stop the pulling operation, the system allows the tools to self-regulate their positioning, compensating for manufacturing tolerances and deflections.
2Ease of operation
If a pulling operation is performed to bring divided tools into close contact, then the tools can be arranged at tentative positions, but small gaps may remain between the respective divided tools
Solution Approach 1:
The control device monitors torque during the pulling operation and uses this feedback to determine when divided tools have been sufficiently brought into contact. When the torque reaches the predetermined value, the system stops the pulling operation, ensuring tools are properly aligned without gaps while maintaining automated operation.
Solution Approach 2:
The patent changes the control parameter from position-based control to torque-based control during the pulling operation. By monitoring torque rather than position, the system can detect when tools are properly contacted despite manufacturing tolerances and mechanical deflections, thereby eliminating gaps while maintaining ease of automated operation.
3Adaptability or versatility
If multiple divided tools are combined to correspond to bending length, then storage and management become simpler, but gaps between tools may cause bending scratches
Solution Approach 1:
The system uses torque feedback during the pulling operation to ensure that multiple divided tools are brought into proper contact with each other. When the torque reaches the predetermined value, the operation stops, guaranteeing that no gaps exist between tools that could cause bending scratches, while maintaining the ability to combine tools for various bending lengths.
Solution Approach 2:
The divided tools themselves provide feedback through their mechanical resistance during the pulling operation. The torque required to bring tools into contact serves as a natural indicator that proper alignment has been achieved, eliminating the need for complex external sensing while preventing gaps that would cause bending scratches.
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 effectively suppresses the occurrence of gaps between divided tools, preventing bending scratches and ensuring accurate tool alignment during the bending process.
Implementation Method 1
a torque of a motor for moving the first automatic tool changer in the left-right direction
Data Source
AI summary
In a first step, a pulling operation is performed with respect to four tools by retaining, in an immovable state, a leftmost tool from among the four tools lined up on a tool mounting unit by means of a left ATC and by moving, toward the left ATC, a rightmost tool from among the four tools by means of a right ATC. In a second step, a movement of the right ATC is stopped when a torque of a motor for moving the right ATC in a left-right direction reaches a preset set value. The first step includes a choosing step of choosing, for the respective left and right ATCs, whether to perform the pulling operation in a state of being abutted against respective side surfaces of the tools or to perform the pulling operation in a state of being engaged with respective engagement holes of the tools.