Press Load Waveform Control for Automatic Abnormality Detection
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Solution Overview
Problem
Existing press systems require time-consuming setup and registration of reference waveforms to determine the state of press working, making them inefficient for quick assessment of press working quality.
Innovation Solution
A press system with a detection unit, reference waveform generation unit, and determination unit that automatically generates a reliable reference waveform based on repeated load waveforms, allowing for simple and precise determination of press working state, including abnormality detection and notification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a reference waveform is registered in advance for determining press working quality, then the determination accuracy is improved, but the setup time and complexity increase
Solution Approach 1:
The press system automatically generates its own reference waveform by detecting and analyzing multiple load waveforms from actual press operations. The system self-learns the normal press characteristics without requiring external manual registration, thereby eliminating the time-consuming setup process while maintaining high determination accuracy through automated statistical analysis of collected data
Solution Approach 2:
The system performs preliminary data collection and analysis by detecting multiple load waveforms before establishing the reference waveform. This preliminary action of gathering and processing operational data enables the system to automatically create an accurate reference baseline without requiring manual intervention during the actual press working determination phase
2Reliability
If multiple load waveforms are collected and analyzed to generate a reference waveform, then the reliability of the reference waveform is improved, but the data processing complexity increases
Solution Approach 1:
The system implements a feedback mechanism where detected load waveforms are continuously compared against the established reference waveform. The determination unit uses this feedback to identify press abnormalities, and the system can iteratively refine the reference waveform based on accumulated data, thereby improving reliability through continuous validation and adjustment while managing complexity through automated feedback loops
Solution Approach 2:
The system transforms multiple complex load waveform datasets into a simplified reference waveform by changing the parameter representation - aggregating multiple waveforms into statistical parameters (such as average, maximum, minimum values) that capture essential press characteristics. This parameter transformation reduces data complexity while preserving the reliability needed for accurate press working determination
Data Source
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AI summary
A press system includes: a detection unit (42) configured to detect a press load applied for pressing a workpiece; a reference waveform generation unit (43) configured to generate a reference waveform for comparison, based on a load waveform of the press load detected by the detection unit; and a determination unit (44) configured to determine whether a press abnormality is present, based on the load waveform of the press load detected by the detection unit and the reference waveform. The press system generates the reference waveform, and therefore, the state of press working can be determined by a simple method.