Press Control Matrix for Fast Workpiece-Specific Setup
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Solution Overview
Problem
Current press operations require extensive manual adjustments by experienced personnel to adapt press process values for shaping workpieces, leading to material waste, high costs, and time-consuming processes due to the complexity of relationships between workpiece parameters and press process values.
Innovation Solution
A press system with a controller using a composition matrix of individually changeable functions to determine and adjust press process values based on workpiece parameters, allowing for flexible and efficient adjustments through an operator interface and input data, including the use of detection devices for real-time feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustment mode is used with experienced personnel, then press process values can be adapted to achieve required tolerance and surface finish, but substantial material consumption is required and adjustment is time-consuming
Solution Approach 1:
The patent replaces the manual mechanical adjustment process with an automated computer-based system. The control device automatically determines press process values using a composition matrix that mathematically models the relationships between press parameters and workpiece quality characteristics, eliminating the need for manual trial-and-error adjustment by experienced operators.
Solution Approach 2:
The system performs preliminary determination of optimal press process values before actual production begins. The composition matrix is pre-calculated based on the specific workpiece and tooling configuration, allowing the press to be quickly adapted to new jobs without requiring extensive manual adjustment and material testing.
2Manufacturing precision
If manual adjustment mode is used with experienced personnel, then press process values can be adapted to achieve required tolerance and surface finish, but substantial quantities of material have to be disposed of as waste parts
Solution Approach 1:
The patent replaces the manual mechanical adjustment process with an automated computer-based system. The control device automatically determines press process values using a composition matrix that mathematically models the relationships between press parameters and workpiece quality characteristics, eliminating the need for manual trial-and-error adjustment by experienced operators.
Solution Approach 2:
The system performs preliminary determination of optimal press process values before actual production begins. The composition matrix is pre-calculated based on the specific workpiece and tooling configuration, allowing the press to be quickly adapted to new jobs without requiring extensive manual adjustment and material testing.
3Adaptability or versatility
If manual adjustment mode is used, then press can be operated in adjustment mode, but very experienced personnel are required and adjustment is cost-intensive
Solution Approach 1:
The patent replaces the manual mechanical adjustment process with an automated computer-based system. The control device automatically determines press process values using a composition matrix that mathematically models the relationships between press parameters and workpiece quality characteristics, eliminating the need for manual trial-and-error adjustment by experienced operators.
Solution Approach 2:
The system enables the press to automatically adjust its own parameters without requiring external expert intervention. The control device uses the composition matrix to self-determine optimal press process values based on workpiece and tooling data, making the press self-sufficient in the adjustment process.
4Productivity
If composition matrix with individually changeable functions is used, then press process values can be quickly determined, but complex mathematical relationships must be modeled
Solution Approach 1:
The patent segments the complex relationship between press parameters and workpiece quality into a matrix of individual functions. Each element of the composition matrix represents a specific relationship between a press parameter and a quality characteristic, allowing the system to handle complexity through modular, organized mathematical representations rather than a single monolithic model.
Data Source
AI summary
A press and a process for operating it, has an upper tool and a lower tool for shaping a workpiece and a work unit including a press drive and/or a drawing device, is controllable by a controller, to perform the shaping process. The controller outputs, to the work unit, press process values, which define the sequence of events of the shaping process. Workpiece parameters characterize, for example, the material and/or the shape and/or at least one dimension and/or quality of the workpiece, which still has to be shaped or has already been shaped. The controller is assigned a composition matrix which contains, for each defined workpiece parameter and for each defined press process value, an individually changeable function, to describe the relationship between every one of the defined workpiece parameters and the defined press process values. This composition matrix allows a quick and rapid adjustment and adaptation of the press.