Instrumented Press Frame Assembly for Consistent Compression Force
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Solution Overview
Problem
Manufacturing processes using presses face challenges in achieving consistency and uniformity of pressure exerted on workpieces, leading to variability in product quality and tooling wear, which affects maintenance schedules.
Innovation Solution
A portable, reconfigurable press frame assembly with a base plate, load cell, displacement transducer, and controller that monitors and adjusts the pressure and displacement during cyclic compression and expansion strokes, providing real-time feedback for improved consistency and tooling maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a press is used to execute manufacturing or assembly steps on workpieces, then productivity is improved through automated processing, but manufacturing precision deteriorates due to inconsistency and uniformity issues in pressure exertion
Solution Approach 1:
The patent implements feedback control by using load cells to continuously monitor the force applied during press operations and using displacement transducers to track the position of the press tool. This real-time feedback is fed to a controller that can detect deviations from the desired force-displacement profile and trigger alerts or adjustments, ensuring consistent pressure application across all workpieces while maintaining automated productivity
Solution Approach 2:
The patent replaces traditional purely mechanical press systems with an instrumented system that incorporates electronic sensors (load cells and displacement transducers) and digital control. This substitution transforms the mechanical system into a smart, monitored system that can detect and report on pressure consistency issues, thereby maintaining productivity while improving manufacturing precision through real-time data acquisition and analysis
2Device complexity
If traditional press systems are used without monitoring, then device complexity is reduced, but measurement precision deteriorates due to lack of real-time pressure and displacement data
Solution Approach 1:
The patent introduces intermediary measurement devices (load cells and displacement transducers) that act as mediators between the mechanical press system and the control system. These intermediaries convert mechanical parameters (force and position) into electrical signals that can be processed by the controller, enabling precise measurement without significantly complicating the overall system architecture. The intermediaries bridge the gap between simple mechanical operation and sophisticated measurement
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
Enhances the consistency and uniformity of pressure applied to workpieces, improving product quality and enabling more precise tooling maintenance schedules by providing real-time data on pressure and displacement.
Implementation Method 1
The load cell includes a beam portion and a flexure portion
Implementation Method 2
The displacement transducer is one of a resistive potentiometer, a linearly-variable differential transformer (LVDT), an inductive device, an encoder, or a laser device
Implementation Method 3
a plurality of springs disposed on the plurality of guideposts; the springs are disposed to urge movement of the first plate in relation to the base plate
Data Source
AI summary
A press frame assembly includes a base plate, a load cell, and an overload protection element; a first plate, a plurality of guideposts disposed on the base plate; a plurality of springs disposed on the plurality of guideposts, a displacement transducer arranged to monitor a linear displacement of the first plate, and a controller, in communication with the load cell and the displacement transducer. The first plate is disposed to translate on the plurality of guideposts, and wherein the springs are disposed to urge movement of the first plate in relation to the base plate. The load cell is arranged to monitor a load exerted upon the base plate. The controller generates a signal that is based upon the load exerted upon the base plate or the linear displacement of the first plate in relation to the base plate.