Press Load Pattern Alignment for Abnormal Pressing Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Pressing apparatuses frequently suffer damage or deterioration due to high-pressure operations, leading to inconsistent product quality as operators struggle to ensure correct pressurization without proper reference values.
Innovation Solution
A pressing apparatus equipped with a storage system for actual and reference data, an adjustor to align data patterns, and a determiner to evaluate the similarity between actual and reference load patterns, allowing for precise assessment of load appropriateness and detection of abnormalities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pressing operation is performed in high pressure, then productivity is improved, but driving devices and driving equipment frequently get damaged or deteriorated
Solution Approach 1:
The system performs preliminary actions by storing reference data patterns representing normal pressing operations before actual pressing occurs. These reference patterns are used to establish baseline expectations for load, position, and time relationships, enabling the system to proactively detect deviations that indicate deterioration or damage before they cause product quality issues
Solution Approach 2:
The system implements continuous feedback by measuring actual pressing operation data (load, position, time) and comparing it against stored reference data patterns. When deviations exceed predetermined thresholds, the system provides feedback signals to alert operators or automatically adjust operations, preventing further damage while maintaining high-pressure productivity
2Reliability
If driving devices are replaced by repairing operation, then reliability is improved, but loss of time occurs
Solution Approach 1:
The system performs preliminary detection by continuously monitoring pressing operations and comparing actual data against reference patterns. This early detection capability identifies deterioration trends before they lead to complete failure, allowing scheduled maintenance during non-productive periods rather than unplanned downtime during operation
Solution Approach 2:
The system performs self-diagnosis by automatically detecting abnormalities in pressing operations through data pattern comparison. This self-monitoring capability enables the system to identify issues without external intervention, allowing operators to plan maintenance during convenient times rather than responding to unexpected failures
3Ease of operation
If pressing operation is performed without checking reference values, then ease of operation is improved, but product quality cannot be ensured
Solution Approach 1:
The system performs self-validation by automatically comparing actual pressing operation data against stored reference data patterns. This self-checking mechanism verifies that pressing operations meet quality standards without requiring manual intervention or expert knowledge from operators, maintaining ease of operation while ensuring manufacturing precision
Solution Approach 2:
The system implements automatic feedback by continuously monitoring pressing parameters and comparing them against reference values. When deviations are detected, the system provides immediate feedback to alert operators or automatically adjust parameters, ensuring product quality without adding complexity to the operating procedure
4Measurement precision
If similarity evaluation of actual data pattern and reference data pattern is performed, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The system uses copying by creating simplified reference data patterns that represent normal pressing operations. These reference patterns serve as templates for comparison against actual operations, enabling accurate anomaly detection through straightforward pattern matching rather than complex analytical algorithms
Solution Approach 2:
The system segments the pressing operation data into distinct parameters (load, position, time) that can be independently analyzed and compared against reference patterns. This segmentation allows the use of simple threshold-based comparison for each parameter while maintaining overall measurement precision, avoiding the need for complex multi-parameter analysis algorithms
Data Source
AI summary
A pressing apparatus 1 includes a storage 27 that stores a plurality of actual data which are load data which was actually measured and which are configured of a first information and a second information, and a plurality of reference data which is a reference for the load data, an adjustor 23 that expands and contracts the first information of at least one of an actual data pattern which is based on the plurality of the actual data stored in the storage 27 and an reference data pattern based on the plurality of the reference data stored in the storage 27 to correspond with each other, and a determiner 24 that determines appropriateness of a load applied to the ram 9 in a pressing operation based on a similarity of the actual data pattern adjusted by the adjustor 23 and the reference data pattern adjusted by the adjustor 23.