Press Tool Spacer Control for Idle Stroke Collision Prevention
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Solution Overview
Problem
Existing sheet metal processing devices with press tools face damage from tool part collisions during idle strokes due to the lack of effective prevention mechanisms, which can occur due to errors in operation or setup, leading to potential damage to critical tool surfaces.
Innovation Solution
An active protection system with actively adjustable spacer devices is implemented to detect idle strokes and prevent collisions by mechanically spacing the tool parts, utilizing sensors and a control device to adjust the spacers, ensuring the tool parts do not collide, and can also function as adjustable tool distances during regular operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If no spacer elements are used during idle stroke, then the device structure remains simple, but the tool parts collide and cause damage to tool surfaces
Solution Approach 1:
The protection system detects idle strokes before they cause damage and activates spacer elements in advance to prevent tool part collision. The sensor detects the absence of a workpiece, the control device identifies the idle stroke condition, and the spacer elements are positioned between tool parts before contact occurs, thereby preventing damage proactively rather than reactively.
Solution Approach 2:
Spacer elements are introduced as intermediary components between the upper and lower tool parts. These spacers physically intervene to maintain a safe distance between tool surfaces during idle strokes, preventing direct contact and potential damage while allowing the press mechanism to continue its cyclic motion.
2Reliability
If rigid tool distances are used, then tool part spacing is maintained, but press force is reduced by up to 40%
Solution Approach 1:
The spacer elements are designed to be dynamically positionable rather than fixed. They can be actively extended or retracted based on operational conditions - extended during idle strokes to prevent collision, and retracted during normal operation to maintain full press force. This dynamic adaptability allows the system to optimize both protection and performance.
Solution Approach 2:
The spacer elements serve multiple functions: they act as protective spacers during idle strokes to prevent tool damage, and can be configured as adjustable tool distances during regular operation to maintain component quality. This multi-functionality eliminates the need for separate rigid spacing mechanisms.
3Reliability
If actively adjustable spacer devices are implemented, then tool collision is prevented during idle strokes, but the device complexity increases
Solution Approach 1:
The protection system is designed to be self-regulating through automated detection and response. Sensors automatically detect idle stroke conditions, the control device processes this information and triggers spacer activation without human intervention, and the spacers self-position to prevent collision. This automation reduces the need for complex manual control mechanisms.
Solution Approach 2:
The system replaces purely mechanical idle stroke protection with a sensor-based detection and control system. Instead of relying on complex mechanical linkages or cams to detect and respond to idle strokes, electronic sensors and control logic are used to identify conditions and activate spacers, simplifying the overall mechanical structure while improving reliability.
Data Source
Figure 1~2
AI summary
The invention relates to a device (1) for processing sheet metal workpieces (M), comprising: - at least one press tool (200) having a lower tool part (210) and an upper tool part (220); - a press (100) having a press table (110) on which the lower tool part (210) is arranged and a press ram (120) to which the upper tool part (220) is attached; and - a protective system for the press tool (200) that detects a idling stroke and prevents a collision between the upper tool part (220) and the lower tool part (210) by means of at least one adjustable spacer device (320). The invention further relates to an adjustable spacer device (320) for use in this device (100).