Press Machining State Estimation Using Zone-Based Load Similarity
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Solution Overview
Problem
Existing technologies struggle to accurately estimate the machining state of a pressing machine, particularly in terms of tool wear, clearance, and chipping, leading to potential defects in the manufacturing process.
Innovation Solution
A machining-state-estimating device and method that utilizes a processor to analyze measurement data from load and distance sensors, generating comprehensive reference data based on criterion reference data and zone shape information to determine the similarity degree between actual and estimated machining states, thereby improving the accuracy of estimating parameters such as punch wear, die wear, clearance, and chipping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If comprehensive reference data is generated based on criterion reference data and zone shape information, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The punched contour is divided into multiple zones, with zone shape information (zone length and retreating amount) calculated for each zone. This segmentation allows the system to handle complex machining states by breaking them down into manageable regional components, improving estimation accuracy without overwhelming the processing system.
Solution Approach 2:
Comprehensive reference data is generated in advance by synthesizing criterion reference data with zone shape information before actual machining state estimation is needed. This preliminary preparation of reference data reduces real-time processing complexity while maintaining high estimation accuracy.
2Measurement precision
If similarity degree determination is performed between comprehensive reference data and measurement data, then measurement precision is improved, but loss of time increases
Solution Approach 1:
Comprehensive reference data including zone-specific characteristics is generated in advance, so that during actual measurement, the system only needs to compare measurement data against pre-prepared reference patterns. This eliminates the need for real-time complex calculations while maintaining high measurement precision.
Solution Approach 2:
The similarity degree determination is performed on zone-specific characteristics rather than entire contour data. By comparing zone length and retreating amount for each zone separately, the system achieves precise measurement with reduced computational burden and faster processing time.
Data Source
AI summary
A machining-state-estimating device includes a storage device and a processor. The storage device stores criterion reference data corresponding to a parameter that defines a machining state of a pressing machine and zone shape information. The zone shape information defines a zone length and a retreating amount. The zone length indicates a length of each of at least one zone representing a punched contour by the pressing machine. The retreating amount indicates a dimensional change of the punched contour from a predetermined position in each of the at least one zone. The processor acquires measurement data indicating a measurement result of a machining load of machining performed by the pressing machine, and generates comprehensive reference data regarding the machining load based on the criterion reference data and the zone shape information. The processor determines a similarity degree that is an index of a degree of similarity between the comprehensive reference data and the measurement data, and estimates a machining state in each of the at least one zone based on the similarity degree determined.