Press Load Monitoring for Die Condition Without Die-Mounted Sensors
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Solution Overview
Problem
Conventional methods for determining die life in punching processes require sensors to be installed in all dies, which is cumbersome and impractical when sensors are not installed, and they fail to account for positional errors during sensor installation and removal.
Innovation Solution
A press machine and die condition monitoring method that utilizes a sensor provided in the press machine to detect load values during punching, calculates a total load and working time based on these values, and generates information on die state without requiring sensors on the dies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are installed in all dies to monitor die condition, then measurement precision is improved, but device complexity and ease of operation deteriorate due to cumbersome installation and removal procedures
Solution Approach 1:
The patent introduces an intermediary sensor system built into the press machine that indirectly measures die condition through load values during punching operations. Instead of directly attaching sensors to each die, the system uses the press machine's existing sensor infrastructure to detect load variations that reflect die state, thereby avoiding the complexity of direct die-mounted sensors while maintaining measurement capability
Solution Approach 2:
The patent replaces the mechanical sensor installation system with an integrated press machine monitoring system. Rather than physically attaching sensors to dies, the system substitutes a centralized detection approach that uses the press machine's inherent sensor capabilities to infer die condition from process parameters, eliminating the need for complex mechanical sensor deployment on each die
2Reliability
If sensors are installed in all dies to monitor die condition, then reliability is improved, but ease of operation worsens due to positional errors during sensor removal and installation
Solution Approach 1:
The system uses load values from the press machine as an intermediary indicator of die condition. By monitoring changes in load characteristics during punching operations, the system reliably determines die state without requiring physical sensors on each die, thereby eliminating operational issues related to sensor installation and removal while maintaining reliable monitoring
Solution Approach 2:
The press machine's sensor system automatically and continuously monitors die condition through load value detection during normal operations. This self-service approach eliminates the need for manual sensor installation and removal, providing continuous reliable data without human intervention or the risk of positional errors during sensor handling
3Device complexity
If sensors are not installed in dies, then device complexity is reduced, but measurement precision deteriorates as die condition cannot be determined
Solution Approach 1:
The patent replaces direct mechanical sensing on dies with an indirect measurement system using the press machine's sensor infrastructure. By substituting die-mounted sensors with press machine-based load detection, the system achieves measurement capability without the complexity of installing and maintaining sensors on each die
Solution Approach 2:
The press machine's sensor system serves multiple functions: it monitors both the punching process parameters and die condition simultaneously. This multi-functional approach allows the system to determine die state using the same sensor infrastructure already present for process control, eliminating the need for separate die-mounted sensors while maintaining measurement precision
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
Enables effective die condition monitoring by calculating total load and working time from sensor data within the press machine, allowing for accurate assessment of die condition without additional sensors on the dies.
Implementation Method 1
a detection unit that detects load values during punching of a workpiece material based on a signal output from a sensor provided in the press machine
Data Source
AI summary
A press machine includes: a detection unit that detects load values during punching of a workpiece material based on a signal output from a sensor provided in the press machine; a storage unit that stores the load values for one cycle of the press machine detected by the detection unit in association with identification information of a die attached to the press machine during detection of the load values; a calculation unit that calculates a total load which is a sum of loads from when an upper die of the die contacts the workpiece material until the punching is completed, based on the load values for one cycle of the press machine; and an information generation unit that generates and outputs information on a state of the die based on the total load calculated based on the load values for one cycle of the press machine detected by the detection unit and the total load calculated based on the load values for one cycle of the press machine stored in association with the die attached to the press machine during the detection of the load values.