Press-Forming Clearance Control Using Three-Axis Die Load Sensing
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Solution Overview
Problem
Existing press-forming apparatuses face instability due to unpredictable variations in material characteristics and environmental factors, making it difficult to maintain appropriate clearance between the blank holder and die, which affects processing stability.
Innovation Solution
A press-forming apparatus equipped with a die load sensor to detect loads in three directions, a controller to calculate the normal force and clearance correction, and drivers to adjust the die and punch positions, ensuring stable processing by accurately maintaining clearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If processing conditions are determined in advance for each material, then production efficiency is improved, but processing stability deteriorates due to material variations and environmental changes
Solution Approach 1:
The patent implements dynamic adjustment of processing conditions through automated clearance correction during press forming operations. The system continuously monitors and adjusts the clearance between die and blank holder based on detected loads, transitioning from static pre-determined conditions to dynamic adaptive control, thereby maintaining processing stability despite material variations.
Solution Approach 2:
The patent employs feedback control by detecting loads on the die during press forming and using this information to calculate and correct clearance deviations. The system forms a closed-loop control where detection results feed back into adjustment actions, enabling real-time compensation for material and environmental variations while maintaining production efficiency.
2Device complexity
If clearance between die and blank holder is fixed, then device complexity is reduced, but manufacturing precision deteriorates due to unpredictable variations
Solution Approach 1:
The patent implements self-service control where the press forming apparatus automatically detects and corrects its own clearance deviations without external intervention. The system uses built-in sensors to monitor loads and automatically calculates and applies correction amounts, enabling the device to self-adjust and maintain high manufacturing precision while keeping the control mechanism relatively simple.
3Manufacturing precision
If clearance correction is performed based on detected loads, then manufacturing precision is improved, but device complexity increases due to additional sensors and control mechanisms
Solution Approach 1:
The patent achieves multi-functionality by using the existing press forming apparatus structure to perform both forming operations and clearance detection/correction functions. The die serves dual purposes as both a forming tool and a load detection point, while the control system integrates multiple functions including load monitoring, clearance calculation, and correction execution, thereby improving precision without proportionally increasing complexity.
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
The apparatus achieves stable processing by accurately calculating and correcting the clearance between the die and blank holder, enhancing processing stability and accuracy.
Implementation Method 1
a die load sensor that detects a load generated on the inclined surface of the die as a load divided into loads in three directions including a pressing direction, a first direction perpendicular to the pressing direction, and a second direction perpendicular to the pressing direction and the first direction
Data Source
AI summary
A press-forming apparatus includes a punch, a die having an inclined surface, and a die holding plate. A blank holder has a holding surface, and a die load sensor detects a load in a pressing direction, a load in a first direction perpendicular to the pressing direction, and a load in a second direction perpendicular to the first direction. A controller calculates a normal force of the die based on the loads in the pressing direction, in the first direction, and in the second direction. The loads are detected by the die load sensor, and the controller calculates the amount of correction of clearance between the die and the blank holder based on the normal force of the die. The first driver moves the die in the pressing direction based on the amount of correction of clearance, and a second driver drives the punch in the pressing direction.