Press Load Monitoring for Sensor-Free Die Condition Tracking
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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 do not 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 cumulative error and installation requirements
Solution Approach 1:
The patent introduces a mediator (reference die with sensor) to indirectly measure the condition of other dies. Instead of installing sensors in every die, a single sensor on a reference die measures load values, and these measurements are used to assess the condition of multiple dies through comparative analysis, eliminating the need for multiple sensor installations
Solution Approach 2:
The patent creates a copy of the measurement system by using load values from a reference die to represent and assess the condition of other dies. The reference die's sensor data is copied and applied to evaluate multiple dies, avoiding the need for direct measurement on each individual die
2Reliability
If sensors are installed in all dies to monitor die condition, then reliability is improved, but ease of operation worsens due to cumulative error and removal/installation requirements
Solution Approach 1:
The patent makes the reference die's sensor system universal by using it to monitor multiple different dies. The same sensor and measurement system serves multiple purposes - monitoring the reference die itself and serving as a reference for assessing other dies, eliminating the need for dedicated sensors on each die
Solution Approach 2:
The reference die acts as an intermediary that enables reliable monitoring of multiple dies without requiring direct sensor installation on each one. The intermediary reference system provides a stable baseline for comparing and assessing the condition of various dies over time
3Measurement precision
If sensors are installed in all dies to monitor die condition, then measurement precision is improved, but loss of time increases due to sensor removal and reinstallation
Solution Approach 1:
The patent performs preliminary action by establishing a reference die with a sensor before actual die monitoring begins. The reference system is set up in advance and remains in place, providing a ready-made measurement baseline that eliminates the need for repeated sensor installations and removals during die changes
Solution Approach 2:
The patent maintains continuity of useful action by keeping the reference sensor installed continuously on the reference die throughout the monitoring period. The measurement system operates continuously without interruption, providing ongoing baseline data for comparing die conditions without requiring repeated setup and teardown of sensors
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, allowing for sensor-free die state assessment and maintenance scheduling based on load and time differences, thus optimizing die maintenance without additional hardware installation.
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
Figure 1
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Figure 4
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.