Press Control Link Matrix for Rapid Setup
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Solution Overview
Problem
Existing press systems require complex and costly adjustments by experienced personnel to achieve accurate and high-quality workpiece formation, often leading to significant material waste due to the difficulty in adapting press operating values to specific forming tasks.
Innovation Solution
A press system with a control device that utilizes a link matrix of individually variable functions to relate workpiece parameters to press operating values, allowing flexible and efficient adjustment of the forming process based on predefined or learned relationships.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If experienced press operators manually adjust press operating values through repeated setting operations and inspection, then the workpiece can be formed within required tolerances and surface quality, but significant amounts of material are consumed as waste and the adjustment process is time-consuming and costly
Solution Approach 1:
The system performs preliminary simulation of the forming process using a digital twin model before actual production. This allows operators to predict workpiece outcomes and adjust press operating values in advance, eliminating the need for repeated trial-and-error setting operations that consume material waste.
Solution Approach 2:
The system implements a feedback mechanism where actual workpiece measurements are compared with simulated predictions, and the digital twin model is continuously refined. This closed-loop feedback enables accurate prediction of forming outcomes without material waste, replacing the traditional manual inspection and adjustment process.
2Manufacturing precision
If experienced press operators manually adjust press operating values through repeated setting operations and inspection, then the workpiece can be formed within required tolerances and surface quality, but the adjustment process requires highly experienced personnel and is time-consuming
Solution Approach 1:
The system performs preliminary simulation of the forming process using a digital twin model before actual production. This allows operators to predict workpiece outcomes and adjust press operating values in advance, eliminating the need for repeated trial-and-error setting operations that consume material waste.
Solution Approach 2:
The system enables operators to independently adjust press operating values using the digital twin simulation tool without requiring highly experienced personnel. The simulation provides intuitive guidance on parameter adjustments, making the press setup process accessible to operators with varying skill levels and significantly reducing adjustment time.
3Manufacturing precision
If traditional manual adjustment methods are used, then press operators can achieve required workpiece quality through experience-based parameter tuning, but the process is complex and costly
Solution Approach 1:
The system introduces a digital twin simulation model as an intermediary between the operator and the physical press. This virtual model simplifies the adjustment process by providing predictive feedback on how parameter changes affect workpiece quality, eliminating the need for complex manual trial-and-error procedures and reducing the skill level required for press setup.
Solution Approach 2:
The system creates a digital copy (digital twin) of the physical press and forming process. This virtual replica allows operators to simulate and optimize forming parameters without affecting actual production, simplifying the adjustment process and reducing the complexity of press setup while maintaining workpiece quality.
4Manufacturing precision
If repeated setting operations and inspection are performed by experienced operators, then the required workpiece tolerances and surface quality can be achieved, but the process consumes significant material that must be disposed of or recycled
Solution Approach 1:
The system performs preliminary simulation of the forming process using a digital twin model before actual production. This allows operators to predict workpiece outcomes and adjust press operating values in advance, eliminating the need for repeated trial-and-error setting operations that consume material waste.
Solution Approach 2:
The system implements a feedback mechanism where actual workpiece measurements are compared with simulated predictions, and the digital twin model is continuously refined. This closed-loop feedback enables accurate prediction of forming outcomes without material waste, replacing the traditional manual inspection and adjustment process.
Data Source
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AI summary
The invention relates to a press (10) and a method for operating it. The press (10) has an upper tool (14) and a lower tool (15) for forming a workpiece (11). A working unit (32) of the press (10), which includes, for example, a press drive (18) and/or a drawing device (20), can be controlled by a control unit (31) to execute the forming process. The control unit (31) outputs press operating values (A1 to An) to the working unit (32), which define the sequence of the forming process. Workpiece parameters (P1 to Pm) characterize the workpiece (11) to be formed or the workpiece (11) that has already been formed, for example, with regard to the material and/or the shape and/or at least one dimension and/or the quality.The control unit (31) is provided with a linking matrix (34) in which, for each defined workpiece parameter (P1 to Pm) and for each defined press operating value (A1 to An), there is an individually modifiable function (f11 to fnm) to describe the relationship between each of the defined workpiece parameters (P1 to Pm) and each of the defined press operating values (A1 to An). Using this linking matrix (34), quick and rapid setup and adjustment of the press (10) is possible.